Phaser 3600
Laser Printer
Warning The following servicing instructions are for use by qualified service personnel only. To avoid personal injury, do not perform any servicing other than that contained in the operating instructions, unless you are qualified to do so. First Printing: September 2008
Prepared By: Xerox Corporation XOG Worldwide Product Training and Information 26600 SW Parkway Wilsonville, OR 97070
Unpublished rights reserved under the copyright laws of the United States. Contents of this publication may not be reproduced in any form without permission of Xerox Corporation. Copyright protection claimed includes all forms and matters of copyrightable materials and information now allowed by statutory or judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as styles, templates, icons, screen displays, looks, etc. Xerox technical training materials and service manuals are intended for use by authorized Xerox service technicians and service partners only and are not for resale. These materials may not be distributed, copied, or otherwise reproduced without prior written consent from Xerox Corporation. XEROX, CentreWare, Phaser, PrintingScout, and Walk-Up are trademarks of Xerox Corporation in the United States and/or other countries. Adobe and PostScript are trademarks of Adobe Systems Incorporated in the United States and/or other countries. Apple, Bonjour, ColorSync, EtherTalk, Macintosh, and Mac OS are trademarks of Apple Computer, Inc. in the United States and/or other countries. PCL is a trademark of Hewlett-Packard Corporation in the United States and/or other countries. Microsoft, Windows, Windows Server, and Windows Vista are trademarks of Microsoft Corporation in the United States and/or other countries. Novell, NetWare, and IPX/SPX are trademarks of Novell, Incorporated in the United States and/or other countries. SunSM, Sun Microsystems, and Solaris are trademarks of Sun Microsystems, Incorporated in the United States and/or other countries. UNIX is a registered trademark in the US and other countries, licensed exclusively through X/Open Company Limited. As an ENERGY STAR partner, Xerox Corporation has determined that this product meets the ENERGY STAR guidelines for energy efficiency. The ENERGY STAR name and logo are registered U.S. marks.
Service Terms
Manual Terms
Various terms are used throughout this manual to either provide additional information on a specific topic or to warn of possible danger present during a procedure or action. Be aware of all symbols and terms when they are used, and always read Note, Caution, and Warning statements. Note A note indicates an operating or maintenance procedure, practice or condition that is necessary to efficiently accomplish a task. A note can provide additional information related to a specific subject or add a comment on the results achieved through a previous action.
Caution
A caution indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in damage to, or destruction of, equipment.
Warning A warning indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, results in injury or loss of life.
Product Terms
Caution: A personal injury hazard exists that may not be apparent. For example, a panel may cover the hazardous area. Danger: A personal injury hazard exists in the area where you see the sign.
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Warning. Danger invisible laser radiation when open. Avoid direct exposure to beam.
Use caution (or draws attention to a particular component). Refer to the manual(s) for information.
0C 32F
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Disconnecting Power
Warning Turning the power Off using the power switch does not completely deenergize the printer. You must also disconnect the power cord from the printers Alternating Current (AC) inlet. Disconnect the power cord by pulling the plug, not the cord. Disconnect the power cord in the following cases:
if the power cord or plug is frayed or otherwise damaged, if any liquid or foreign material is spilled into the product, if the printer is exposed to any excess moisture, if the printer is dropped or damaged, if you suspect that the product needs servicing or repair, whenever you clean the product.
Immediately before handling any semiconductor components assemblies, drain the electrostatic charge from your body. This can be accomplished by touching an earth ground source or by wearing a wrist strap device connected to an earth ground source. Wearing a wrist strap will also prevent accumulation of additional bodily static charges. Be sure to remove the wrist strap before applying power to the unit under test to avoid potential shock. After removing a static sensitive assembly from its anti-static bag, place it on a grounded conductive surface. If the anti-static bag is conductive, you may ground the bag and use it as a conductive surface. Do not use freon-propelled chemicals. These can generate electrical charges sufficient to damage some devices. Do not remove a replacement component or electrical sub-assembly from its protective package until you are ready to install it. Immediately before removing the protective material from the leads of a replacement device, touch the protective material to the chassis or circuit assembly into which the device will be installed. Minimize body motions when handling unpacked replacement devices. Motion such as your clothes brushing together, or lifting a foot from a carpeted floor can generate enough static electricity to damage an electro-statically sensitive device. Handle ICs and Erasable Programmable Read-Only Memories (EPROMs) carefully to avoid bending pins. Pay attention to the direction of parts when mounting or inserting them on Printed Circuit Boards (PCBs).
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Warning Labels
Read and obey all posted warning labels. Throughout the printer, warning labels are displayed on potentially dangerous components. As you service the printer, check to make certain that all warning labels remain in place.
Safety Interlocks
Make sure all covers are in place and all Interlock Switches are functioning correctly after you have completed a printer service call. If you bypass an Interlock Switch during a service call, use extreme caution when working on or around the printer.
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Warning Do not touch any electrical component unless you are instructed to do so by a service procedure.
Warning Do not try to manually rotate or manually stop the drive assemblies while any printer motor is running.
Warning This printer uses heat to fuse the toner image to paper. The Fuser is VERY HOT. Turn the printer power Off and wait at least 5 minutes for the Fuser to cool before attempting to service the Fuser or adjacent components. viii Phaser 3600 Printer Service Manual
Regulatory Information
Xerox has tested this product to electromagnetic emission and immunity standards. These standards are designed to mitigate interference caused or received by this product in a typical office environment.
Reorient or relocate the receiver (device being interfered with). Increase the separation between the printer and the receiver. Connect the equipment into an outlet on a circuit different from that which the receiver is connected. Consult the dealer or an experienced radio/television technician for help.
Any changes or modifications not expressly approved by Xerox could void the user's authority to operate the equipment. To ensure compliance with Part 15 of the FCC rules, use shielded interface cables.
Canada (Regulations)
This Class B digital apparatus complies with Canadian ICES-003. Cet appareil numrique de la classe B est conforme la norme NMB-003 du Canada.
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European Union
The CE mark applied to this product symbolizes Xeroxs declaration of conformity with the following applicable Directives of the European Union as of the dates indicated: December 12, 2006: Council Directive 2006/95/EC as amended. Approximation of the laws of the member states related to low voltage equipment. December 15, 2004: Council Directive 2004/108/EC as amended. Approximation of the laws of the member states related to electromagnetic compability. This product, if used properly in accordance with the user's instructions, is neither dangerous for the consumer nor for the environment. To ensure compliance with European Union regulations, use shielded interface cables. A full declaration of conformity, defining the relevant directives and referenced standards, can be obtained from your Xerox Limited representative.
Manual Organization
The Phaser 3600 Printer Service Manual is the primary document used for repairing, maintaining, and troubleshooting the printer. Use this manual as your primary resource for understanding the operational characteristics of the printer and all available options. This manual describes specifications, theory, and the diagnosis and repair of problems occurring in the print engine and attached options. Also included are detailed replacement procedures, parts lists, and wiring diagrams. The Phaser 3600 Printer Service Manual contains these chapters: Introductory, Safety, and Regulatory Information: This section contains important safety information and regulatory requirements. Chapter 1 - General Information: This chapter contains an overview of the printers operation, configuration, specifications, and consumables. Chapter 2 - Theory of Operation: This chapter contains detailed functional information on the printer components. Chapter 3 - Error Messages: This chapter provides detailed troubleshooting procedures for error messages generated by resident diagnostics. Chapter 4 - General Troubleshooting: This chapter contains general information on troubleshooting the printer. In addition, this chapter includes troubleshooting methods for situations where error indicators are not available. Chapter 5 - Print-Quality Troubleshooting: This chapter focuses on techniques to correct image quality problems associated with the printer output. Chapter 6- Cleaning and Maintenance: This chapter provides periodic cleaning procedures for the printer. Chapter 7- Service Parts Disassembly: This chapter contains removal procedures for spare parts listed in the Parts List. A replacement procedure is included when necessary. Chapter 8- Parts List: This chapter contains exploded views of the print engine and optional Field Replaceable Units (FRUs), as well as part numbers for orderable parts. Chapter 9- Plug/Jack and Wiring Diagrams: This chapter contains the plug/jack locations and the wiring diagrams for the printer. Reference: This section provides a list of acronyms and abbreviations
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Table Of Contents
Table Of Contents
Service Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Symbols Marked on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Power Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Electrostatic Discharge Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Service Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 General Information
Printer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Printer Options and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Consumable and Service Part Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Parts of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Error and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Printer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Printer Location and Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Printer Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Functional Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Environmental Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Media and Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2 Theory of Operation
Phaser 3600 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Summary of the Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Print Cartridge and Print Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Printer Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Paper Path Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Duplex Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Print Engine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Image Processing Assembly and Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Laser Scan Unit (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Motor Drive Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Feed Assembly Process and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Transfer Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Duplex and Tray Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Duplex Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Tray 2 and Optional Tray 3 Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Paper Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Automatic Paper Pick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Laser Scan Unit (LSU) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Laser Light Intensity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Toner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Fuser Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Sensor Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Sensor Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Sensors in the Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 High Voltage Power Supply (HVPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Switching Mode Power Supply (SMPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
3 Error Messages
Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Using the Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Service Diagnostics Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Entering Service Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Service Diagnostic Control Panel Button Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Diagnostic Test Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Troubleshooting Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Jam At Tray [1] [2] [3] (Jam 0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Jam At Top (Jam 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Jam At Exit (Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Jam At Rear (Duplex Jam 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Jam At Duplex (Duplex Jam 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge . . . . . . . . . . . . . . . 3-18 Close Fuser Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Close Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error. . . . . . . . . . . . . . . . . . . . . . . 3-20 Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Output Tray is Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
4 General Troubleshooting
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Recommended Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Control Panel Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 No Control Panel Display after Power Is Turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Control Panel LED is On, Control Panel Display Is Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Power Supply Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Taking Voltage Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5 Print-Quality Troubleshooting
Print-Quality Problems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Repeating Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Repeating Defects Measurement Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Control Panel (Internal) Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Table Of Contents Image-Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Blank Print (No Print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Light or Undertone Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Background Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Residual Image or Ghosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Faded or Missing Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Random Spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Repeating Bands, Lines, Marks, or Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Unfused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Horizontal Band, Voids, or Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Tray 2 Pick-Up Assembly and Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Pick-Up Gear and Bearing (PL 1.1.21). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Tray 2 Feed Roller (PL1.3.59.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Tray 2 Pick Roller (PL1.3.59.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Tray 2 (PL2.1.0) and Optional Tray 3 (PL2.2.0) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Duplex Unit (PL2.3.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Main Drive and Registration Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Main Drive Assembly (PL 1.1.18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Main Board (PL 1.1.19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Main Solenoid (PL 1.1.25). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Registration Assembly (PL 1.1.12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Transfer Roller (PL 1.1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Exit Roller (PL 1.3.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Exit Gear (PL 1.3.9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Outbin Full Actuator (PL 1.3.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 Outbin Full Sensor (PL1.3.21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Duplex Roller (PL 1.3.11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Exit Solenoid (PL 1.1.16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Feed Idle Unit (PL 1.3.50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Pre-transfer Lamp (PTL) Board (PL 1.3.71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Developer Drive Assembly (PL 1.1.17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51 Joint Board (PL 1.3.61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Paper Size Sensor (PL 1.3.14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53 Fuser Assembly (1.3.80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Fuser Interlock Switch (PL 1.3.77) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Fuser Exit Sensor (PL 1.3.76) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Fuser Thermostat (PL 1.4.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Fuser Thermistor (PL 1.4.40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Heat Roller (PL 1.4.53) and Bushing (PL 1.4.44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Dual-lamp (PL 1.4.56) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Pressure Roller (PL 1.4.66) and Bushing (PL 1.4.50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Laser Scan Unit (PL 1.1.15). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70 LSU Lower Cover (PL 1.3.48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 Left Side Cooling Supply Fan and Duct (PL 1.1.31). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Cover Open Board and Sensor (PL 1.3.47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 High Voltage Power Supply (HVPS) (PL 1.1.29.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Switched Mode Power Supply (PL 1.1.29.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
8 Parts List
Serial Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Serial Number Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Using the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 PL 1.1 Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 PL 1.2 Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 PL 1.3 Frame Assembly (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 PL 1.3 Frame Assembly (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 PL 1.4 Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 PL 2.1 Tray 2 Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 PL 2.2 Tray 3 Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26 PL 2.3 Duplex Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Table Of Contents
A Reference
Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Index
General Information
In this chapter...
Printer Configurations Consumable and Service Part Life Expectancy Parts of the Printer Control Panel Printer Specifications Media and Tray Specifications
Chapter
General Information
Printer Configurations
Print Features and Configurations Printer Configurations Features Maximum Print Speed Letter Memory (Optional) Up to 512 MB Optional if the original DIMM is replaced with 256MB RAM DIMM and the second slot has a 256MB RAM DIMM PostScript and PCL Fonts Default Resolution Maximum Resolution 500-Sheet Feeder (Tray 3) Network Interface 3600_B 40 ppm 64 MB 3600V_B 40 ppm 64 MB 3600_N 40 ppm 128 MB 3600V_N 40 ppm 128 MB
Yes 600 x 600 dpi 600 x 600 dpi 1200 x 1200 1200 x 1200 dpi dpi Optional Not Optional Optional Not Optional Optional Yes
Yes
Yes
Automatic 2-Sided Printing Optional (Separate Duplex Unit) USB, Parallel Interface Yes
Options and Supplies Printer Option Memory Item 64 MB additional RAM memory 128 MB additional RAM memory 256 MB additional RAM memory Duplex Unit 500-Sheet Feeder Standard-Capacity Print Cartridge (7,000 pages) High-Capacity Print Cartridge (14,000 pages) Extra High-Capacity Print Cartridge (20,000 pages) Metered/Pagepack Print cartridge (20,000 pages) Xerox lubricant Plastislip grease Part Number 097S03759 097S03760 097S03761 097S03387 097S03385 106R01370 106R01371 106R01372 106R01369 043E00550
Optional Units
Cartridges
Gear Lubricant
1-2
General Information
Print Life Standard Capacity 7,000 pages High Capacity 14,000 pages Extra High Capacity 20,000 pages Metered/Pagepack 20,000 pages
Service Parts Fuser Assembly Transfer Roller Feed Roller Kit Retard Roller Separator Pad 150,000 pages 150,000 pages 150,000 pages 150,000 pages 150,000 pages
Note The service parts are not tracked with an NVRAM counter and there is no replace or low warnings associated with these service parts.
1-3
General Information
Tray 1 (MPT) Tray 1 (MPT) Release Tray 2 On/Off Switch Paper Gauge
s3600-001
Rear View
Rear Door Network Port (optional for 3500B) USB Port IEEE 1284 Parallel Port Tray 3 Optional Cable Connector Duplex Unit (optional)
s3600-112
1-4
General Information
Control Panel
The Control Panel has three components:
Multi-colored Light Emitting Diode (LED) light Alphanumeric display Six-button cluster
Control Panel Buttons Button Return CANCEL MENU UP DOWN OK Function Returns to the prior higher level menu structure, if available. Terminates the current action. Cycles through all of the top level menu items. Scrolls up one menu item within a menu list. If you continually press this control, the menu items will wrap. Scrolls up one menu item within a menu list. If you continually press this control, the menu items will wrap. Executes the highlighted menu item.
Menu Map
The Menu Map is a visual representation of the Control Panel settings and information pages. All Menu Map settings are documented in the User Guide.
1-5
General Information
Printer Specifications
Printer Location and Clearance
Place the printer in a dust-free area where the temperature range is 50 degrees F to 89 degrees F (10 degrees C to 32 degrees C) and the relative humidity range is between 20% to 80%.
Place the printer in an area where there is adequate space for ventilation, operation, and servicing. See the clearance graphic below. Do not block or cover the slots and openings on the printer. The printer can overheat without adequate ventilation. For altitudes under 2,050 meters (6,726 feet), use the Low Altitude setting. For altitudes over 2,050 meters (6,726 feet), use the High Altitude setting. Do not place the printer near a heat source. Do not place the printer in direct sunlight. Do not place the printer in line with the cold air flow from an air conditioning system. Place the printer on a level, solid surface with adequate strength for the weight of the printer.
100 mm (4 in.)
s3600-003
1-6
General Information
Net Dimension with Option 396*453*501mm Tray (15.6"*17.8"*19.7") Toner Toner Packing SET with 10K toner cartridge SET w/o toner cartridge Consumable toner cartridge Set + Consumables Packing Weight 314 x 225 x 116 mm 368 x 286 x 169 mm 17.30kg (38.14lb) 15.46kg (34.06lb) 10K : 1.85kg (4.08lbs) 20K : 2.06kg (4.54 lbs) 19.15 kg (42.2lb) with 10K toner cart. 22.46kg (49.50lb)
Functional Specifications
Print Operability Characteristic Printing process Color medium Resolution / Addressability Operating Modes Specification Non-Impact Electrophotography Monochrome True 600 x 600 dpi Addressable 1200 x 1200 dpi Standby Mode: Print engine capable of making prints in less than 9 seconds. Sleep/ Low Power/ Power Saver Mode: 31 seconds from completion of a print. Letter: Up to 40 ppm A4: Up to 38 ppm 10 seconds or less Power-on Boot: 40 seconds or less
Continuous Operating Printing Speed (ppm = pages per minute) First Print-Out (in seconds) Warm-Up Time
1-7
General Information
Print Quality Property Resolution Characteristic Normal Line Width @ 600dpi Line Width @ 1200dpi Dot Diameter @ 600dpi Dot Diameter @ 1200dpi RET Halftone (Gray Scale) Blackness Yes 256 levels >1.20 Specification Up to 1200 x 1200 dpi effective output
Homogeneity of Halftone at five points on page must be 0.1 Halftone Printable Area Letter A4 Non-Printable Area Envelope Other Media Toner Fixing Black (100% Solid) Halftone Magnification Horizontal (applied to 177.8mm length) Vertical (applied to 241.3mm length) Printing Skew Tray 1 (MPT) 20 % = 0.17 50 % = 0.49 80 % = 0.91 208 x 271 mm 200 x 289 mm 10mm(0.4") from edge(Top/Bottom/Left/Right) 4mm(0.16") from edge(Top/Bottom/Left/Right) 80% 70% < 1.0 mm (0.04 ) ( 0.5 % ) < 3.0 mm (0.12 ) ( 1.2 % ) < 1.5 mm (0.06 ) Simplex & Horizontal < 2.0 mm (0.08 ) Duplex & Horizontal < 2.0 mm (0.08 ) Simplex & Vertical < 2.5 mm (0.10 ) Duplex & Vertical Tray 2 < 1.5 mm (0.06 ) Simplex & Horizontal < 2.0 mm (0.08 ) Duplex & Horizontal < 2.0 mm (0.08 ) Simplex & Vertical < 2.5 mm (0.10 ) Duplex & Vertical Optional Tray 3 < 2.0 mm (0.08 ) Simplex & Horizontal < 2.5 mm (0.1 ) Duplex & Horizontal < 2.5 mm (0.10 ) Simplex & Vertical < 3.0 mm (0.12 ) Duplex & Vertical
1-8
General Information
Electrical Specifications
Power Rating and Line Voltages Characteristic Primary line voltages Primary line voltage frequency range Power consumption Specification 110 - 127 V Printer - (100 - 135 V) 13 amp circuit 220 - 240 V Printer - (180 - 264 V) 7-8 amp circuit 100 - 135 V Printer - 50/60 Hz + 3 Hz 220 - 240 V Printer - 50/60 Hz + 3 Hz Printing: 550 Watts (average) Sleep: under 10 Watts
Environmental Specification
Operating Environment Characteristic Optimal Temperature Optimal Humidity Altitude Operating Low Altitude Setting High Altitude Setting Transportation Acoustic Noise Idle Printing Specification 10 - 30 degrees C (50-60 degrees F) 20% - 80% Relative Humidity 0 - 2,500 meters (8,200 ft.) 0 - 2,050 meters (6,726 ft.) 2,050 - 2,500 meters (6,726 - 8,200 ft.) 0 - 6,092 meters (20,000 ft.) 35.0db or less 49.0db or less
Mode Simplex from Tray1 Simplex from MP Simplex from SCF Duplex from Tray1
Specification Less than 56.0 dBA Less than 56.0 dBA Less than 59.0 dBA Less than 59.0 dBA Less than 35.0 dBA Less than 50.0 dBA Less than 60.0 dBA
Measurement
1-9
General Information
Media type Media weight Sensing Standard Cassette Tray Capacity Media sizes Media types Media weight Sensing
1-10
General Information Media Tray Capacity Optional Cassette Capacity Tray Media sizes Media types Media weight Sensing Duplex Supporting Media sizes Media types Media weight 500 sheets@75g A4/A5/Letter/Legal/Executive/Folio/ Oficio/ISO B5/JIS B5 Plain paper 16~28lb (60 to 105g/) Paper Empty Sensor Optional A4/Letter/Legal/Folio/Oficio Plain paper 20~24lb (75 to 90g )
Media Input Size/Weight Source Tray 1 Media Types Paper, Envelope, Paper Labels, Transparency. Paper, Cardstock Min: 76 mm x 127 mm (3 in. x 5 in.) Max: Legal Paper Paper Media Sizes Media Weights
A4, Letter, Legal, Folio, 16 lb. ~ 28 lb. Executive, ISO and JISB5, A5 (60 ~ 176 gsm) 16 lb. ~ 43 lb. A4, Letter, Legal, Folio, Executive, ISO and JISB5, A5, (60 ~ 105 gsm) A6, Statement Monarch, COM 65# Cover 10, C5, DL, 3 x 5 16 lb. ~ 28 lb. A4, Letter, Legal, Folio, Executive, ISO and JISB5, A5 (60 ~ 105 gsm) A4, Letter, Legal, Folio 20 lb. ~ 24 lb. (75 ~ 90 gsm)
Tray 2
Tray 3 Duplex
Media Print Speed Property Speed Mode Simplex Duplex Specification Up to 38 ppm in A4 (40 ppm in Letter) 26 ipm in A4 (27 ipm in Letter) (Letter A4 Folio Oficio Legal) First-Page Output Time (FPOT) from standby from sleep/power save mode from cold status Warm Up Time from sleep/power save mode from cold status Less than 9 sec Less than 40 sec Less than 49 sec Less than 31 sec Less than 40 sec
1-11
General Information Media Print Speed Toner save setting unit SWS PSU LUI(Local UI) Duplex Print Simplex Manual Duplex Duplex Support Support (30%) Support(UI2.0) Support N/A Optional
1-12
Theory of Operation
In this chapter...
Phaser 3600 Operational Overview Printer Paper Path Printer Controls Sensor Functions Printer Controls
Chapter
Theory of Operation
2-2
Theory of Operation
Charge Roller Drum Developer Roller (D/R) Supply Roller (S/R) Metering Blade Cleaning Blade
Cleaning Roller LSU 0.20 mW -400 ~ -50020V Doctor Blade -1.5 ~ -1.30KV Charging Roller Cleaning Blade OPC Drum V0: -680V VL: -620V
-500 ~ -60020V
Developing Roller
Supply Roller
Transfer Roller
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Print Modes
The Phaser 3600 Laser Printer provides two print modes: 1. Draft mode: Uses a combination of reduced toner output and the lowest resolution (300 x 300 dpi) to extend print cartridge life. 2. Enhanced mode: Used for printing on plain paper with an addressable resolution of 1200 x 1200 dpi.
2-3
Theory of Operation
Heat Roller
Idler Tray 1 No Paper Sensor Feed 2 Idler Feed 2 Roller Retard Roller Feed 1 Roller Tray 2 Pick Roller Duplex Rollers Duplex Sensor Registration Roller Transfer Roller Fuser Exit Roller Fuser Exit Sensor Pressure Roller
Retard Roller
Media that meets printer specifications can be fed from Tray1 (MPT) and Tray 2, or the Optional Tray 3. If you use thick paper with a weight of more than 105 gsm (60 lbs), you must insert the paper into Tray 1 (MPT) and select the paper type. Paper will exit the printer to the face down top tray. A door at the rear of the printer provides access for jam clearance. All major components of the printer are explained in greater detail under Printer Controls on page 2-10.
2-4
Theory of Operation
Paper Transport
The Registration Assembly continues to drive the paper into the transfer area, where the image is transferred from the drum to the paper. After the image transfers, the paper continues to the Fuser Assembly for the fusing the process. In the Fuser Assembly, the Heat Roller is heated by a heat element and the paper passes in between the Heat Roller and the pressure roller, where toner melts onto the paper to form a permanent image. The temperature of the heat roller is monitored by a Thermistor that sends signals to the Main Board. The Fuser Assembly drives the paper into the Exit Rollers, which drive the paper into the output tray. When printing the first side of a duplex print job, the drive direction is reversed when the Exit Sensor is actuated. Paper is then directed into the Duplex Unit for printing on the second side.
2-5
Theory of Operation
Image Processing and the Main Board Laser Scan Unit Main Drive Assembly Feed assembly Process and Components Transfer Roller Assembly Fuser Assembly
Control Panel (CN16) Toner Sensor Board (CN6) Cover Open (CN26) Duplex Solenoid (CN11) Laser Unit (CN9) Developer Thermistor (CN8) Rear Fan (CN4) Motor (CN20) PTL (CN21) LVPS (CN19) Power (CN22) USB (CN2) Duplex (CN17) Main Motor (CN18) Exit Sensor (CN23) Joint Board (CN24) Optional 3rd Tray (CN25) RAM DIMM 1 (CN14) RAM DIMM 0 (CN12) Ethernet (CN1)
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2-6
Theory of Operation
2-7
Theory of Operation 4. Miscellaneous Paper Functions A paper arrangement function uses a stopper roller and a weight without an electric actuator. It also includes an additional paper separating function, a driving control function, and a multi feeding prevention function. The Feed Roller transfers paper along the paper path and is also part of jam detection.
Fuser Assembly
The Fuser Assembly contains the entire Fuser Subsystem and is a field replaceable unit. The Fuser Assembly contains the following components:
Heat Element and Heat Roller:Two quartz lamps operate as the heating elements, which generate the heat inside the Heat Roller. The Heat Roller melts the toner so it adheres to the paper. Pressure Roller: Provides pressure on the opposite side of the print media so the Heat Roller can embed the melted toner in the media. Thermistor: Monitors the surface temperature of the Heat Roller. This information is used to control the heat lamp and thus keep the Heat Roller at the correct temperature. Thermostat: Prevents overheat damage when unexpected system faults occur.
2-8
Theory of Operation
Feeding Method : Cassette Type Feeding Standard : Center Loading Feeding Capacity : Cassette 500 Sheets(75g/ , 20lb Paper Standard) Paper Detecting Sensor : Photo Sensor Paper Size Sensor : Yes
2-9
Theory of Operation
Printer Controls
Paper Size Control
The paper size selection for Tray 2 and Tray 3 is set by moving the paper guide in the tray. This in turn sets the plastic fingers on the side of the paper tray to a specific postion.The position of the fingers activates the correct combination of the three paper size switches, located in each paper tray slot, for the selected paper size. Additionally, the back of the tray must be pulled down in order to select the two largest sizes; US Folio and Legal. Not all sizes can be used in both trays. See Media and Tray Specifications on page 10 for a complete listing of the media types for each tray. Additional media types can be used in Tray 1 (MPT). After inserting the media in Tray 1, use the Control Panel controls to select the media type.
LEGAL 14" US FOLIO (LEGAL 13) A4 LETTER EXECUTIVE B5 B5, JIS-B5 A5 No Tray
2-10
Theory of Operation
Laser Diodes: Generates the laser beams. Rotating Polygon Mirror: Scans the laser beam across the drum, axially. Beam Detector: Synchronizes the left margin. Optical Lens System: Focuses the laser beam onto the surface of the drum. Mirrors: Reflect the laser beam onto the surface of the drum.
The polygon motor speed is steady, Laser Failure but the Hsync signal is not generated.
Toner Control
Print Cartridge installation and Toner Level are detected by the Print Cartridge Interconnect Board and the associated signals are supplied to the Main Board. The CRUM not only detects cartridge presence, it also determines whether it is a genuine Xerox cartridge. When the toner remaining falls to 15%, the printer displays a low toner message on the Control Panel display.
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Theory of Operation
When the power voltage for the printer is too high or too low, the Fuser is stopped to protect the Fuser. When the AC voltage is not applied to the Fuser control circuit, the fuser will not work and a Fuser Low Heat Error will occur. When the temperature of the Fuser is too high, an Engine Overheat error occurs if the cooling operation is insufficient Description When warming up, the Fuser has been lower than 60 degrees C for over 35 seconds. Error Message Fuser Failure
Stand-by: Engine Low Heat Error Lower than 130 degrees C for over 10 seconds. Printing: Up to 2 consecutive pages: Lower than 155 degrees C for over 7 seconds. From 3 consecutive pages: Lower than 25 degrees C than the fixed fusing temperature over 7 seconds. Temperature is higher than 230 degrees Engine Over Heat C over 10 seconds. Error
2-12
Theory of Operation
Sensor Functions
Sensor Types
The types of sensors used vary with function. In general, there are three types in use:
Photo Sensors
Two types of photo sensors are used, photo-reflective and photo-receptive. Photo-reflective sensors use light reflected back from an object to detect its presence. Photo-receptive sensors use an actuator or the object itself to block the light path to detect an object or condition. Photo-reflective sensors have the light emitter and light receiver aligned on a single surface. Output of the photo-receptor is High (> +4.5 V) when light is being reflected back and Low (< +.3 V) when it isnt. Photo-receptive sensors consist of a LED in one arm of a U-shaped holder, and a photo-transistor in the other arm. When the sensing area is vacant, nothing is between the arms of the sensor, light falls on the photo-receptor sending the signal High. If the light is interrupted, the photo-transistor goes Low.
Actuator
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2-13
Theory of Operation
Microswitches
Microswitches are used primarily as paper size sensors and cover interlocks. They are in a normally open state, and close when actuated. A bank of microswitches is used to detect paper size in the universal trays. Microswitches also employ hooks or catches for retention in the bracket or frame.
Actuator Button
Contact
Blade
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Thermistors
Thermistors have a known value of resistance whose value varies with temperature. Used primarily in the Fuser for temperature sensing.
2-14
Theory of Operation
Sub Toner Low Board and Sensor Fuser Interlock Switch Paper Size Sensor
Output Tray Full Sensor Fuser Exit Sensor Cover Open Interlock Switch
Duplex Sensor
Paper Tray Empty Sensor Tray 1(MPT) Feed Sensor Tray 2 Paper Empty Sensor Tray 3 Paper Empty Sensor
Tray 1(MPT) Paper Empty Sensor Tray 2 Feed Sensor Tray 3 Feed Sensor
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Theory of Operation Secondly, the signal generated by the sensor tells the Main Board that the paper is almost at the transfer area and it is time to start the xerographic process. It is important that the leading edge of the paper enters the transfer area at the same time as the leading edge of the developed image on the drum.
Duplex Sensor
The Duplex Unit slides into the rear of the printer above Tray 2. The Main Board senses the presence of the Duplex Unit and paper in the Duplex unit through the Duplex connector. As paper leaves the Fuser Assembly and is picked up by the Exit Rollers, the drive direction is reversed to send the paper into the Duplex Unit. As the paper leaves the Duplex Unit, it activates the Duplex Sensor within the unit. This activates the Feed Roller to position the paper for printing on the second side of the paper.
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Theory of Operation
Power Supplies
High Voltage Power Supply (HVPS)
The HVPS section generates and supplies the following voltages:
The Bias, Supply, and Charge voltages are used by the Print Cartridge. The power distribution section receives AC voltage and creates the required DC outputs (3.3 VDC, 5 VDC, and 24 VDC) to power the printer components. It also supplies AC voltage to the Fuser Assembly.
CON02
CON01
CON03
CON06 CON05
CON04
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2-17
Theory of Operation
FUSER MHV
OPC
THV
CN1
CN4 CN3
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2-18
Error Messages
In this chapter...
Troubleshooting Overview Service Diagnostics Service Diagnostics Menu Map Troubleshooting Error Messages
Chapter
Error Messages
Troubleshooting Overview
This section covers troubleshooting procedures for the Phaser 3600 Laser Printer. When an error first occurs, record the error message and code and then cycle power to the printer to see if the error recurs. To troubleshoot image-quality problems, see Image-Quality Troubleshooting on page 5-9.
3-2
Error Messages
Service Diagnostics
The printer has built-in diagnostics to aid in troubleshooting problems. The Service Diagnostics Menu provides a means to test sensors, motors, switches, clutches, fans and solenoids. Diagnostics also contain built-in test prints, cleaning procedures, printer status and some NVRAM access. Service diagnostics are to be executed through the control panel by a certified service technician only.
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1. Turn the printer power OFF. 2. While holding down the OK button (1), turn the printer back ON (2). Note Refer to the Diagnostic Test Menu Map on page 3-5 to see the description of all component tests.
3-3
Error Messages
1 2
5 1. Cancel Button 2. Return Button 3. On-line/Data/Error LED 4. Menu Button 5. Status/Error Messages and Menus 6. Up Arrow Button 7. OK Button 8. Down Arrow Button
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6 3 4 7 8
The alphanumeric display provides status messages and control panel menus. Diagnostic Control Panel Buttons Button BACK Function Returns to the prior higher level menu structure, if available. Stops the actively running test. Terminates the current test. Cycles through all of the top level menu items. Scrolls up one menu item within a menu list. This control does not wrap. Used to increment values in tests requiring user input. Scrolls up one menu item within a menu list. This control does not wrap. Used to increment values in tests requiring user input. Enters the highlighted menu. Executes the current test item. Used to select the value entered by the user.
CANCEL MENU UP
DOWN
OK
3-4
Error Messages
Tray 1 If the Tray is opened, "Open" Cassette message will be displayed and if *(T1 thru T3 not, "Closed" displayed refer to Tray 1 thru Tray3 respectfully. T4 is not supported Tray 2 Cassette Tray 3 Cassette Fuser Door If the Tray is opened, "Open" message will be displayed and if not, "Closed" displayed If the Tray is opened, "Open" message will be displayed and if not, "Closed" displayed If the Door is opened, "Open" message will be displayed and if not, "Closed" displayed.
Tray 2 Cassette
Tray 3 Cassette
3-5
Error Messages Diagnostic Menu Map Options Main Menu Sensor Status (Test 1) Sub Menu Registration Sensor Description/Function The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. Control Panel Display Registration Sensor [Without Paper] [With Paper] T1 Feed Sensor [Without Paper] [With Paper] T2 Feed Sensor [Without Paper] [With Paper] T3 Feed Sensor [Without Paper] [With Paper] T4 Feed Sensor [Without Paper] [With Paper] Exit Sensor [Without Paper] [With Paper] DJam1 Sensor [Without Paper] [With Paper]
T1Feed Sensor
T2 Feed Sensor
T3 Feed Sensor
T4 Feed Sensor
Exit Sensor
DJam 1 Sensor
3-6
Error Messages Diagnostic Menu Map Options Main Menu Sub Menu Description/Function The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. Control Panel Display Outbin Sensor [Normal] [Full]
Bypass Empty
T1 Paper Empty
T2 Paper Empty
T3 Paper Empty
T4 Paper Empty
T1 PSize0 Sensor
T1 PSize1 Sensor
T1 PSize2 Sensor
T2 PSize0 Sensor
T2 PSize1 Sensor
3-7
Error Messages Diagnostic Menu Map Options Main Menu Sub Menu Description/Function The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The first value lists normal display before touching the sensor, and the second value lists normal display after touching the sensor. The motor will run on the forward direction or stop. The motor will run on the forward direction in half speed mode. Control Panel Display T2 Psize2 Sen [Low] [High]
T3 PSize0 Sensor
T3 PSize1 Sensor
T3 PSize2 Sensor
T4 PSize0 Sensor
T4 PSize1 Sensor
T4 PSize2 Sensor
Motors (Test 2)
Main Mtr Fwd [On] [Off] Main Mtr Slow [On] [Off] Dev Mtr Nor [On] [Off] Dev Mtr Slow [On] [Off] Duplex Mtr Fwd [On] [Off] T2 Feed Motor [On] [Off]
Dev Mtr Nor The motor will run on the forward direction in normal speed. Dev Mtr Slow Duplex Mtr Fwd T2 Feed Motor The motor will run on the forward direction in half speed. The motor will run on the forward direction. The motor will run on the forward direction or stop.
3-8
Error Messages Diagnostic Menu Map Options Main Menu Motors (Cont.) Sub Menu T3 Feed Motor T4 Feed Motor Fans (Test 3) Fuser Fan Fuser Fan Rdy SMPS Fan SMPS Fan Rdy Duplex Fan Clutches/ Solenoids (Test 4) T1 P-up Clutch T2 P-up Clutch T3 P-up Clutch T4 P-up Clutch Bypass Clutch Duplex Sol. Fuser Ctrl (Test 5) Fuser Bias Temp Control Description/Function The motor will run on the forward direction or stop. The motor will run on the forward direction or stop. The fan will run or stop. Check whether the fan is in the locked state. The fan will run or stop. Check whether the fan is in the locked state. The fan will run or stop. The clutch will run or stop. The clutch will run or stop. The clutch will run or stop. The clutch will run or stop. The clutch will run or stop. The solenoid will run or stop. The bias will have the previously saved value. The fuser unit will control the power for fixing and displaying the current temperature on the panel. The target temperature is 160 degrees. Control Panel Display T3 Feed Motor [On] [Off] T4 Feed Motor [On] [Off] Fuser Fan [On] [Off] Fuser Fan Rdy [Ready] [Not Ready] SMPS Fan [On] [Off] SMPS Fan Rdy [Ready] [Not Ready] Duplex Fan [On] [Off] T1 P-up Clutch [On] [Off] T2 P-up Clutch [On] [Off] T3 P-up Clutch [On] [Off] T4 P-up Clutch [On] [Off] Bypass Clutch [On] [Off] Duplex Sol. [On] [Off] Fuser Bias [On] [Off] Temp Control [On] [Off] [xxx]
The Control Panel displays a digital Fuser Temp equivalent [xxx] of the analog value. [xxx] The Control Panel displays a digital Inner Temp equivalent [xxx] of the analog value. [xxx]
3-9
Error Messages Diagnostic Menu Map Options Main Menu LSU Ctrl (Test 6) Sub Menu LD Power1 LD Power2 Laser Motor Description/Function The display shows the previously saved value. The display shows the previously saved value. The motor will run or stop. Control Panel Display LD Power1 [On] [Off] LD Power2 [On] [Off] Laser Motor [On] [Off] Laser Ready [Normal] [Fault]
Laser Ready When the LSU is ready to print (laser diode ON with a stable motor speed), the message, Normal displays. Dev Control (Test 7) THV Plus Bias THV Minus Bias DEV Bias The panel displays the previously saved bias value. The panel displays the previously saved bias value. The panel displays the previously saved bias value.
THV Plus Bias [On] [Off] THV Minus Bias [On] [Off] DEV Bias [On] [Off] DEV AC Bias [On] [Off] DEV Vpp Bias [On] [Off] MHV Bias [On] [Off] PTL [On] [Off] Erase Lamp [On] [Off]
DEV AC Bias The panel displays the previously saved bias value. DEV Vpp Bias MHV Bias PTL Erase Lamp The panel displays the previously saved bias value. The panel displays the previously saved bias value. The Pre-transfer Lamp will be either on or off. The lamp will be either on or off.
TR Cur Read The Control Panel displays a digital TR Cur Read equivalent [xxx] of the analog value. [xxx] CR Cur Read Test Print (Test 8) The Control Panel displays a digital CR Cur Read equivalent [xxx] of the analog value. [xxx] Print [On] [Off] 2.00 1.00 N/A 1.03
Pattern Print The printer prints a pattern test page into Tray (MPT). T2 Version T3 Version T4 Version DPX Version Displays Tray 2 version Displays Tray 3 version N/A
3-10
Error Messages
After paper pick, paper is not fed. After paper pick, paper enters the printer but does not reach the Feed Sensor in the specified time. After paper pick, the feed sensor turns ON and tries to pick again but the paper does not reach the Feed Sensor in the specified time.
The leading edge of the paper passes the Feed Sensor but the trailing edge does not pass through the Feed Sensor in the specified time. (The Feed Sensor cannot be OFF). The leading edge of the paper passes the Feed Sensor, but the paper cannot reach the Exit Sensor in the specified time. (The Exit Sensor cannot be ON).
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Error Messages
A print cartridge is not detected. A non-Xerox print cartridge is installed. The Toner Sensor Board is malfunctioning.
Fuser Failure, Engine Fuser Low Heat Error, Engine Overheat Error
Fuser is damaged or malfunctioning.
Laser Failure
The Laser Scan Unit is malfunctioning or damaged.
3-12
Error Messages
Tray 1 Assembly, PL1.2.35 Tray 1 Solenoid, PL1.1.26 Registration Assembly, PL1.1.12 Pick Roller, PL1.3.2.5 Main Board, PL1.1.19
Troubleshooting Procedure Table Step 1. Actions and Questions Check the side guides for the inoperative tray for damage or improper seating. Are guides damaged or loose? Check the surface of the Pick Roller for dirt or damage. Are the rollers dirty or damaged? Yes Replace the Tray (page 7-14). No Go to Step 2.
2.
Clean rollers with a Go to Step 3. soft cloth very slightly dampened with water or replace (page 7-25) if damaged. Go to Step 4. Replace Registration Assembly (page 7-41).
3.
4.
5.
Use service diagnostics to check Replace the Main the operation of the tray solenoid. Board (page 7-39). Do the tray solenoids operate correctly?
3-13
Error Messages
Registration Assembly, PL1.1.12 Paper Exit Sensor, PL1.3.76 Switched Mode Power Supply
Troubleshooting Procedure Table Step 1. Actions and Questions Clean the paper path of any obstructions, dirt or debris. Did this correct the problem Use service diagnostics to test the operation of the Registration Assembly. Does the Registration Assembly operate correctly? Use service diagnostics to test the Exit Sensor. Does the sensor operate correctly? Replace the Fuser Assembly (page 7-54) and retest. Did this correct the problem? Yes Complete. No Go to Step 2.
2.
Go to Step 3.
Replace the Registration Assembly (page 7-41). Replace the Exit Sensor page 7-56
3.
Go to Step 4.
4.
Complete.
3-14
Error Messages
Troubleshooting Reference Table Applicable Parts Exit Roller, PL1.3.6 Paper Exit Sensor, PL1.3.76 Fuser Assembly, PL1.4.1 Switched Mode Power Supply, PL1.1.29.2 Main Board, PL1.1.19
Wiring and Plug/Jack Map References Map 3- SMPS Board on page 9-6 Main Drive/Joint Board and Optional Tray Wiring Diagram on page 9-15
Step
Action and Questions Is the Paper Exit Sensor or the actuator damaged or binding?
Yes Repair or replace the actuator and/or Paper Exit Sensor (page 7-56). Replace the Exit Roller (page 7-44).
No
Go to Step 2.
2.
Inspect the Exit Roller. Use service diagnostics to test the main drive to exit. Is the exit roller damaged or binding? Visually inspect the Fuser. Is there paper wrapped around the Fuser rollers? Is the Fuser Assembly operational. Do the Fuser gears rotates when the Main motor is on? Use the embedded diagnostics to check the Exit Roller. Are the rollers operational?
Go to Step 3.
3.
Go to Step 4.
4.
Replace the Fuser Assembly (page 7-54). Replace the SMPS (page 7-76).
5.
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Error Messages
Transfer Roller, PL1.1.7 Duplex Exit Sensor, PL2.3.15 Duplex Roller, PL2.3.4 Duplex Unit, PL2.3.0 Main Board, PL1.1.19
Step 1.
Actions and Questions Does paper jam after reversal but before reaching the Duplex Sensor? Replace Transfer Roller Shaft Assembly (page 7-43). Does problem recur? Inspect the Duplex Unit. Is any paper wrapped around the Duplex Rollers? Are the rollers damaged or binding? Is there damage to the duplex assembly.
Yes Go to Step 2.
No Go to Step 3.
2.
Replace Duplex Unit Complete (page 7-37). Remove obstruction Go to Step 5. and clean rollers. Replace the Duplex Roller (page 7-47). Replace the Duplex Unit (page 7-37). Go to Step 7. Replace Main Board (page 7-39).
4.
5. 6.
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Error Messages
Transfer Roller, PL1.1.7 Duplex Exit Sensor, PL2.3.15 Duplex Roller, PL2.3.4 Main Board, PL1.1.19 HVPS Board, PL1.1.29.1
Troubleshooting Procedure Table Step 1. Actions and Questions Does the paper jam after reversal but before reaching the Duplex Exit Sensor? Use service diagnostics to test the Duplex Exit Sensor. Does the sensor operate correctly? Inspect the Exit and Duplex Rollers for any signs of damage or binding. Replace the Duplex Unit. Does the problem still occur? Yes Replace the Transport Roller (page 7-43). Go to Step 3. No Go to Step 2.
2.
3.
Replace the Duplex Roller (page 7-47). Replace the Main Board (page 7-39).
4.
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Error Messages
Check Cartridge, Invalid Print Cartridge, Non-Xerox Cartridge, Replace Print Cartridge
Wiring and Plug/Jack Map References Map 2- Main Board on page 9-5 Main Drive/Joint Board and Optional Tray Wiring Diagram on page 9-15
Print Cartridge, PL1.1.34 Toner Sensor Board, PL1.3.47.2 Main Board, PL1.1.19
Step Action and Questions 1. Open the top cover and ensure that the Print Cartridge is properly seated. Does the error clear after reseating the cartridge? Check the Print Cartridge for damage. Does the cartridge contain toner and appear to be operating properly? Reseat all harness connections to the Toner Sensor (CRUM) Board. Does the error clear? Check continuity between the Toner Sensor (CRUM) Board and CN7 on the Main Board.
Yes Complete
No Go to Step 2.
2.
Go to Step 3.
3.
Complete
Go to Step 4.
4.
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Error Messages
Troubleshooting Reference Table Applicable Parts Fuser Assembly, PL1.4.1 Main Board, PL1.1.19 Switched Mode Power Supply (SMPS), PL1.1.29.2
Step Action and Questions 1. Visually inspect the fuser door close tab for damage. Is the tab broken? Is the sensor and actuator on the Fuser operating correctly. Is the Printer operational?
Yes Replace the Fuser (page 7-54) then go to Step 3. Replace the Main Board (page 7-39). Complete
No Go to Step 2.
2.
Replace the Fuser (page 7-54) then go to Step 3. Replace the SMPS (page 7-76).
Troubleshooting Procedure Table Step 1. Action and Questions Visually inspect the top cover and the top cover actuator. Is the Top Cover or actuator damaged? Use diagnostics to test the Cover Open Board. Does the Cover Open board function properly? Yes No
2.
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Error Messages
Fuser Failure, Engine Fuser Low Heat Error, or Engine Fuser Over Heat Error
Troubleshooting Reference Table Applicable Parts Fuser Assembly, PL1.4.1 Switched Mode Power Supply, PL1.1.29.2 Main Board, PL1.1.19
Wiring and Plug/Jack Map References Map 3- SMPS Board on page 9-6 Main Drive/Joint Board and Optional Tray Wiring Diagram on page 9-15
Troubleshooting Procedure Table Step Action and Questions 1. 2. Does the error report Fuser Failure? Check the thermistor. Is the circuit open? Check the line voltages across the thermostats. Are they open? Is the Fuser getting power? Yes Go to Step 2. Replace the Fuser (page 7-54). Replace the Fuser (page 7-54). Replace the Fuser (page 7-54). No Go to Step 3. Replace the Main Board (page 7-39). Go to Step 4.
3.
4.
Replace the SMPS (page 7-76). Replace the Main Board (page 7-39).
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Error Messages
Laser Failure
Troubleshooting Reference Table Applicable Parts
Wiring and Plug/Jack Map References Map 1- LSU and Fuser on page 9-4 Main Drive/Joint Board and Optional Tray Wiring Diagram on page 9-15
Step 1.
Actions and Questions Reseat the connections to the laser and visually inspect the Laser Scan Unit for damage. Did this correct the problem?
Yes Complete
No Go to Step 2.
2.
Use diagnostics to check the laser Replace the Laser Scan Unit motor function. Is the Laser Scan Unit Operational? (page 7-70).
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Error Messages
Main Board, PL1.1.19 Tray Full Actuator, PL1.3.8 Tray Full Sensor, PL1.3.95
Step 1.
Actions and Questions Check the Tray Full Sensor and actuator for obvious damage. Is the actuator damaged? Use diagnostics to test the Tray Full Sensor. Does the sensor operate correctly?
Yes Replace the actuator (page 7-45). Replace the Main Board (page 7-39).
No Go to Step 2.
2.
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General Troubleshooting
In this chapter...
Servicing Instructions Preventive Maintenance Procedure Control Panel Troubleshooting Power Supply Troubleshooting
Chapter
General Troubleshooting
Servicing Instructions
The service flowchart is an overview of the path a service technician should take, using this manual, to service the print engine and options. Step 1: Identify the Problem 1. Verify the problem reported and check for any error codes and write them down. 2. Print normal customer prints and service test prints and look for any of the following:
a. any image quality problems in the test prints. b. any mechanical or electrical abnormalities present. c. any unusual noise or smell coming from the printer.
3. View the fault and jam histories and look at the total print count for the printer. 4. Verify the AC input power supply is within proper specifications by measuring the voltage at the electric outlet while the printer is running. Step 2: Inspect and Clean the Printer 1. Switch OFF printer power and disconnect the AC power cord from the wall outlet. 2. Verify the power cord is free from damage or short circuit and is connected properly. 3. Remove the Print Cartridge and protect it from light, then inspect the printer interior and remove any foreign matter, obstructions, or loose toner. 4. Inspect the interior of the printer for damaged wires, loose connections, toner leakage, and damaged or obviously worn parts. 5. Do not use solvents or chemical cleaners to clean the printer interior. 6. Do not use any type of oil or lubricant on printer parts. 7. Use only an approved toner vacuum. 8. Clean all rubber rollers with a lint-free cloth, dampened slightly with cold water. 9. Replace any service items that have reached their 150,000 end-of-life. Step 3: Find the Cause of the Problem 1. Use the Repair Analysis Procedures to find the cause of the problem. 2. Use Diagnostics to check printer and optional components. 3. Use the Wiring Diagrams to locate test points. 4. Take voltage readings at various test points as instructed in the appropriate troubleshooting procedure. Step 4: Correct the Problem 1. Use the Parts List to locate a part number. 2. Use the Repair and Adjustments Procedures to replace the part. Step 5: Final Checkout 1. Test the printer to be sure you have corrected the initial problem and there are no additional problems present.
4-2
General Troubleshooting
Recommended Tools
Toner vacuum cleaner Clean water Clean, dry, lint-free cloth Black light protective bag
4-3
General Troubleshooting
4-4
General Troubleshooting
4-5
General Troubleshooting
4-6
Print-Quality Troubleshooting
In this chapter...
Print-Quality Problems Overview Repeating Defects Control Panel (Internal) Test Print Image-Quality Troubleshooting
Chapter
Print-Quality Troubleshooting
See the approved media list, Media and Tray Specifications on page 1-10, for media that has been tested and approved for use with the Phaser 3600 Laser Printer.
Print a test page to see if the image-quality problem still exists. See Test 8 in the Diagnostic Test Menu Map on page 3-5. When analyzing a image-quality defect, first determine if the defect is repeating or random. Repeating defects can often be associated with a particular component. Inspect the surfaces of all rollers in the paper path for obvious defects.
5-2
Print-Quality Troubleshooting
Repeating Defects
Some image-quality problems can be associated with specific assemblies, the most common problems and the associated assemblies are listed below. Also, see the specific image-quality troubleshooting procedure for more information.
Print Cartridge
Streaks Fine Lines Banding in Process Direction Uneven Density Voids Repeating Defects
Transfer Roller
Toner on the back side of the printed page (simplex mode) Light Prints Repeating Defects Spots on Image
Fuser
5-3
Print-Quality Troubleshooting
Use supported paper from a fresh, unopened ream Print five copies of the test print. Discard the first two prints and retain the remaining prints for imagequality analysis.
Deletions
Inspect the test print for the presence of deletions or unprinted spots. If these are found, see Repeating Bands, Lines, Marks, or Spots on page 5-22.
5-4
Print-Quality Troubleshooting
Fusing
Rub the image three times at the indicated points with a soft cloth or tissue. The toner should not lift off of the surface of the print. If the image smears or toner lifts off the image onto the cloth, see Unfused Image on page 5-24.
s3600-080
Resolution
Observe the three resolution check points on several test prints.
Ensure that the 2 pixel horizontal, vertical, and diagonal lines are clear and continuous. The diagonal lines might appear to be narrower than the others. Characters in the text paragraphs should be uniform and equal in density. The halftone patches should be uniform in appearance.
If the image does not meet the criteria, see Light or Undertone Print on page 5-11 or Background Contamination on page 5-15.
5-5
Print-Quality Troubleshooting
5-6
Print-Quality Troubleshooting
s3600-083
s3600-082
5-7
Print-Quality Troubleshooting
Skips or Smears
Check the test print in the indicated areas for loss, stretching, or distortion of the image in bands across the process direction that make the image seem distorted, blurred, or compressed. If these faults are observed, see Horizontal Band, Voids, or Streaks on page 5-27.
s3600-084
5-8
Print-Quality Troubleshooting
Image-Quality Troubleshooting
The following table provides examples and descriptions, possible causes, and the solutions for troubleshooting various image or printing defects that may be observed in the Phaser 3600 Laser Printer.
Initial Actions
Check the paper transfer path. Ensure the transfer path is free of debris.
Example Print
Transfer Roller, PL1.1.7 Registration Assembly, PL1.1.12 Laser Scan Unit, PL1.1.15 Print Cartridge, PL1.1.34 HVPS, PL1.1.29 Main Board, PL1.1.19
Blank Print
Troubleshooting Procedure Table Step 1 2 Actions and Questions Print a Demo page. Is the entire area still blank? Check the paper condition. Is the paper dry, a recommended type, and loaded in the correct position? Yes Go to step 3. Go to step 3. No Go to step 2. Replace the paper. Go to step 4.
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge.
5-9
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 4 Actions and Questions Check the Registration Assembly. Is there any damage to the Registration Assembly? Yes Replace the Registration Assembly (page 7-41). No Go to step 5.
Complete. Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Check the laser beam path. Is there any debris between the Laser Scan Unit and Transfer Roller? Check the wiring harness connector between the Laser Scan Unit and the Main Board. Are the connectors securely connected? Check the Main Board for correct installation. Reseat the Main Board (page 7-39). Does the image quality improve? Check the HVPS for correct installation. Reseat the HVPS Board (page 7-75). Does the image quality improve? Replace the Laser Scan Unit (page 7-70). Does the image quality improve? Remove any debris. Go to step 8.
Go to step 6.
Go to step 7.
Complete.
Complete.
Go to step 10.
10
Complete.
5-10
Print-Quality Troubleshooting
Initial Actions
Check the paper path for any debris. Check the Control Panel settings for proper print settings.
Example Print
Transfer Roller, PL1.1.7 Laser Scan Unit, PL1.1.15 Print Cartridge, PL1.1.34 HVPS, PL1.1.29 Main Board, PL1.1.19
Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Go to step 4.
4 5
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge. Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Replace the Main Board (page 7-39). Does the image quality improve? Complete.
Complete.
Go to Step 7.
5-11
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 7 Actions and Questions Check the laser beam path. Is there any debris between the Laser Scan Unit and Transfer Roller? Replace the Laser Scan Unit (page 7-70). Does the image quality improve? Check the HVPS for correct installation. Reseat the HVPS Board. Does the image quality improve? Yes Remove the debris, then go to step 5. Complete. No Go to step 8.
Go to step 9.
Complete.
5-12
Print-Quality Troubleshooting
Black Print
The entire image is black.
Initial Actions
Check the paper transfer path. Ensure there is no debris on the transfer path.
Example Print
Transfer Roller, PL1.1.7 Laser Scan Unit, PL1.1.15 Print Cartridge, PL1.1.34 HVPS, PL1.1.29 Main Board, PL1.1.19
Black Print
Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Go to step 4.
4 5
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge. Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Complete.
5-13
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 6 Actions and Questions Check the wiring and connectors between the Laser Scan Unit and the Main Board. Are the connectors securely connected? Replace the Laser Scan Unit (page 7-70). Does the image quality improve? Check the Main Board for correct installation. Reseat the Main Board (page 7-39). Does the image quality improve? Check the HVPS for correct installation. Reseat the HVPS Board (page 7-75). Does the image quality improve? Replace the Print Cartridge. Does the image quality improve? Yes Go to step 7. No Reconnect the connectors, then go to step 7. Go to step 8.
Complete.
Complete.
Go to step 9.
Complete.
Go to step 10.
10
Complete.
5-14
Print-Quality Troubleshooting
Background Contamination
There is toner contamination on all or most of the page. The contamination appears as a very light gray dusting.
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path. Clean the Pre-transfer Lamp (PTL).
Example Print
Transfer Roller, PL1.1.7 Registration Assembly, PL1.1.12 Print Cartridge, PL1.1.34 HVPS, PL1.1.29
Background Contamination
Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Is the original document normal? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Go to step 4.
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge.
5-15
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 5 Actions and Questions Check the Transfer Roller. Are there any damages to the Transfer Roller? Check the Registration Assembly. Is there any damage to the Registration Assembly? Check the HVPS for correct installation. Reseat the HVPS (page 7-75). Does the image quality improve? Yes Replace the Transfer Roller (page 7-43). Replace the Registration Assembly (page 7-41). Complete. No Go to step 6.
Go to step 7.
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
5-16
Print-Quality Troubleshooting
Verify the paper is within the printer specifications (refer to page 1-10).
Example Print
Transfer Roller, PL1.1.7 Registration Assembly, PL1.1.12 Print Cartridge, PL1.1.34 Fuser, PL1.4.1 Main Board, PL1.1.19
Residual Image/Ghosting
Warning Ensure to wait for the Fuser to cool down before starting the procedure. Troubleshooting Procedure Table Step 1 Actions and Questions Check the printing usage. Did the user print the same image at a large volume? Check the Transfer Roller. Are there any damages to the Transfer Roller surface? Check the Registration Assembly. Is there any damage to the Registration Assembly? Yes Go to step 2. No Go to step 3.
Replace the Transfer Roller (page 7-43). Replace the Registration Assembly (page 7-41).
Go to step 3.
Go to step 4.
Check the Print Cartridge for correct Complete. installation. Reseat the Print Cartridge. Does the image quality improve? Replace the Print Cartridge. Does the image quality improve? Replace the Fuser (page 7-54). Does the image quality improve? Complete. Complete.
Go to step 5.
5 6
5-17
Print-Quality Troubleshooting
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Is the original document normal? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Go to step 4.
Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position?
Go to step 5.
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge.
5-18
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 6 Actions and Questions Check the Registration Assembly. Is there any damage to the Registration Assembly? Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Yes Replace the Registration Assembly (page 7-41). Complete. No Go to step 7.
5-19
Print-Quality Troubleshooting
Random Spots
Spots of toner are randomly scattered across the page.
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Random Spots
Warning Ensure to wait for the Fuser to cool down before starting the procedure. Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check for any debris on the document glass and the CVT window. Are there any debris? Check for spots regular intervals. Are there any spots on the page? Yes Go to step 3. No Go to step 2.
2 3
Complete. Go to step 4.
Complete.
5-20
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 5 6 Actions and Questions Yes No Go to step 6. Go to step 7.
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge. Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Check the Fuser for correct installation. Reseat the Fuser. Does the image quality improve? Complete.
Complete.
5-21
Print-Quality Troubleshooting
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Registration Assembly, PL1.1.12 Transfer Roller, PL1.1.7 Laser Scan Unit, PL1.1.15 Print Cartridge, PL1.1.34
Repeating Defects
Warning Ensure to wait for the Fuser to cool down before starting the procedure. Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check the document path. Is there any debris on the document path? Check for band or spots regular intervals. Are there any bands or spots on the page? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Remove the debris. Refer to Repeating defects info on page page 5-3.
Complete. Go to step 4.
Go to step 5.
Check the Print Cartridge for damages. Replace the Is the Print Cartridge damaged? Print Cartridge.
Go to step 6.
5-22
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 6 Actions and Questions Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Check the Transfer Roller. Are there any damages on the roller surface? Check the Registration Assembly for correct installation. Reseat the assembly (page 7-41). Does the image quality improve? Check for debris in the laser beam path between the Laser Scan Unit and the Registration Assembly. Is there any debris? Does the image quality improve? Yes Go to step 7. No Replace the paper. Go to step 8.
Go to step 9.
Go to step 10.
10
Complete.
5-23
Print-Quality Troubleshooting
Unfused Image
The toner image is not completely fused to the paper. The image easily rubs off.
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Unfused Image
Warning Ensure to wait for the Fuser to cool down before starting the procedure. Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Verify the media type selection. Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Yes Go to step 2. No Complete.
2 3
Go to step 3. Go to step 4.
Select the correct media. Replace the paper. Replace the Print Cartridge.
Check the Print Cartridge for damages. Go to step 5. Is the Print Cartridge damaged?
5-24
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 5 Actions and Questions Check the Fuser for correct installation. Reseat the Fuser (page 7-54). Does the image quality improve? Yes Complete. No Replace the Fuser (page 7-54).
Skew
The printed image is not parallel with both sides of the paper.
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Retard Assembly, PL1.3.49 Tray 1 (MPT) Assembly, PL1.2.35 Separator Pad Assembly, PL1.3.4 Feed2 Idle Unit, PL1.3.50 Registration Assembly, PL1.1.12 Duplex Unit, PL2.3.0
Skew 2
Troubleshooting Procedure Table Step 1 Action and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Go to step 4.
5-25
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 4 Action and Questions Yes No Complete.
Check the Print Cartridge for correct Go to step 5. installation. Reseat the Print Cartridge. Does the error still occur? Check the Separator Pad Assembly. Is there damage or debris on the Separator Pad?
Remove the Go to step 6. debris or replace the Separator Pad Assembly (page 7-20). reseat the paper Go to step 7. and go to step 7. Go to step 8. Complete.
Check for a skewed tray. Is the skewed paper fed from Tray 1 (MPT)? Check the Tray 1 (MPT) Side Guides. Reset the Paper Guides. Does the error still occur? Replace the Tray 1 (MPT) Feed Roller (page 7-14). Does the error still occur? Check the Registration Assembly and Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the error still occur?
Go to step 9.
Complete.
Replace the Registration assembly (page 7-41), then go to step 10. Go to step 11.
Complete.
10
Check the skewed mode through the Duplex Unit. Is the skewed paper fed the from the Duplex? Check the Duplex Unit for correct installation. Reseat the Duplex Roller (page 7-47). Does the error still occur? Check additional paper trays for correct installation. Reseat the trays. Does the error still occur? Replace the Tray 2 Feed Roller (page 7-30). Does the error still occur?
Go to step 12.
11
Go to step 12.
Complete.
12
Go to step 13.
Complete.
13
Complete.
5-26
Print-Quality Troubleshooting
Initial Actions
Check the paper transfer path. Ensure there are no debris on the transfer path.
Example Print
Registration Assembly, PL1.1.12 Transfer Roller, PL1.1.7 Laser Scan Unit, PL1.1.15 Print Cartridge, PL1.1.34
Troubleshooting Procedure Table Step 1 Actions and Questions Print a demo page. Does the error still occur when printing? Print a customer application page. Does the error still occur? Check the document path. Are there any debris on the paper path? Check for bands regular intervals Are there any bands on the page? Check the Print Cartridge for damage. Is the Print Cartridge damaged? Check the paper condition. Is the paper dry, recommended type, and loaded in the correct position? Yes Go to step 3. No Go to step 2.
2 3
Go to step 3. Remove the debris. Refer to page 5-4. Replace the Print Cartridge. Go to step 7.
Complete. Go to step 4.
4 5 6
5-27
Print-Quality Troubleshooting Troubleshooting Procedure Table (continued) Step 7 Actions and Questions Check the Registration Assembly. Is there any damage to the Registration Assembly? Check the Transfer Roller for correct installation. Reseat the Transfer Roller (page 7-43). Does the image quality improve? Check for debris in the laser beam path between the Laser Scan Unit and the Registration Assembly. Is there any debris? Does the image quality improve? Yes Replace the Registration Assembly (page 7-41). Complete. No Go to step 8.
Go to step 9.
Go to step 10.
10
Complete.
5-28
Chapter
Recommended Tools
Toner vacuum cleaner Clean water Clean, dry, lint-free cloth Black light-protective bag
General Cleaning
Perform the following general cleaning steps as indicated by the printers operating environment.
Caution
Never apply alcohol or other chemicals to any parts of the printer. Never use a damp cloth to clean up toner. If you remove the Print Cartridges, place them in a light-protective bag or otherwise protect them as exposure to light can quickly degrade performance and result in early failure. 1. Record number of sheets printed. 2. Print several sheets of paper to check for problems or defects. 3. Turn the printer power Off and disconnect the power cord. 4. Remove the Transfer Unit, Fuser, Print Cartridges, Duplex Unit (if installed), and Side Covers before cleaning. 5. Remove the Rear Cover and clean the Rear Cover Fan to remove excess dust. 6. Remove the Top Cover and clean the Main Fan to remove excess dust. 7. Ensure that all cover vents are clean and free of obstructions. 8. Remove any debris or foreign objects from the Fuser, Transfer Unit, Print Cartridges, Duplex Unit, and inside of the printer. 9. Remove and clean the paper trays. 10. Clean all rubber rollers with a lint-free cloth slightly dampened with cold water.
6-2
s3600-091
Caution
Do not expose the Print Cartridge to light for more than 5 minutes. Cover the Print Cartridge to avoid damage. 1. Open the Top Cover. 2. Remove the Print Cartridge. 3. Use a dry lint-free cloth to wipe any dust and/or spilled toner from the Print Cartridge area. Remove any paper debris from the area.
6-3
6-4
Service Overview General Notes on Disassembly Covers and Control Panel Tray 1 (MPT) Assembly Tray 2 (PL2.1.0) and Optional Tray 3 (PL2.2.0) Replacement Duplex Unit (PL2.3.0) Main Drive and Registration Assemblies Frame Assembly Fuser Assembly (1.3.80) Laser Scan Unit (PL 1.1.15) Power Supplies
Chapter
Service Overview
This section contains the removal and replacement procedures for selected parts of the printer according to the Service Parts List. Not all Replacement Procedures are included in this Service Manual. In most cases, to reinstall a part, simply reverse the Removal Procedure shown. In some instances, the Replacement Procedure is included, because it may contain special steps. For specific assemblies and parts, see Parts List on page 8-1.
Warning
Remove the Fuser Assembly or wait at least 5 minutes after you have switched OFF printer power for the Fuser to cool before you work on or around the Fuser.
7-2
Service Parts Disassembly 5. Tray 2 can interfere with the removal of many printer parts. Remove Tray 2 before further disassembly. Note Part names that appear in the disassembly procedures may not exactly match the names that appear in the Parts List. For example, a part called the Registration Transport Assembly may appear on the Parts List as Assembly, Transport Regi.
Caution
Many parts are secured by plastic tabs. DO NOT over flex or force these parts. Do not over torque the screws threaded into plastic parts. Always use the correct type and size screw. Using the wrong screw can damage tapped holes. Do not use excessive force to either remove or install either a screw or a printer part. A spring hook is required for removal and replacement of the various springs in the printer. Springs can be damaged using pliers or other tools for this task.
Warning Unplug the AC power cord from the wall outlet before removing any printer part.
7-3
Fastener Types
The following table lists the primary types of Posi-Drive screws used to assemble the printer. The procedures provide dimensional specifications for screws being removed. Posi-Drive Screw Types used in the Printer Type Selftapping, plastic Application Shape Characteristics 1. Silver colored. 2. Screw thread is coarse compared to metal screw. 3. Screw tip is thin.
1. Black colored. 2. Screw thread is coarse compared to metal screw. 3. Screw has a flange. 4. Screw tip is thin. 1. Silver colored. 2. Diameter is uniform.
Parts etc.
Sheet Metal, with flange
Sheet Metal
1. Silver colored. 2. Screw has a flange. 3. Diameter is uniform.
Parts etc.
Sheet Metal
Caution
Use care when installing self-tapping screws in plastic. To properly start the screw in plastic, turn the screw counter-clockwise in the hole until you feel the screw engage the threads, then tighten as usual. Failure to properly align or over tighten the screw can result in damage to previously tapped threads. Always use the correct type and size screw. Using the wrong screw can damage tapped holes. Do not use excessive force to remove or install either a screw or a printer part. Note Unless specifically noted in the text, all screws listed in the disassembly chapter for the Phaser 3600 are 10mm self tapping screws.
7-4
The notation (item X) points to a numbered callout in the illustration corresponding to the disassembly procedure being performed. The notation PLX.X.X indicates that this component is listed in the Parts List. Bold arrows in an illustration show direction of movement when removing or replacing a component.
Left
Rear
Front
Right
s3600-008
7-5
s3600-027
4. Remove the right side access cover. 5. To remove from the printer, slide the Right Cover towards the rear of the printer to release the 3 tabs on the top of the cover and 3 hooks on the bottom of the cover. Replacement Note When reinstalling the cover, insert the 3 bottom hooks first, then slide the cover from the rear to the front. Make sure the cover is securely behind the 3 tabs.
7-6
s3600-028
Replacement Note Before reinstalling the cover, remove the duplex unit. When reinstalling the cover, insert the 3 bottom hooks first, then slide the cover from the rear to the front. Make sure the cover is securely behind the 3 tabs.
7-7
s3600-040
3. While facing the Rear Cover, lift up on the right hinge pin, slide the Rear Cover to the right to free the left hinge pin, then remove the Rear Cover from the printer.
7-8
s3600-108
3. Disconnect the interim connector (P/J4) from the three-wire harness to the fan. 4. Flex two hooks on one side of the fan to release and remove.
Hooks
s3600-109
7-9
s3600-031
7. Release 3 tabs, one on the left, one on the right, and one on the rear of the Top Cover. Replacement Note You may need to open the Rear Cover slightly before reinstalling the Top Cover.
7-10
s3600-010
8. Disconnect the Control Panel wiring harness (CN17) from the Main Board. Replacement Note Note the position of the wiring harness and ferrite coil for reassembly.
7-11
s3600-104
7-12
s3600-074
7-13
Caution
Tray 1 and the Knock-Up Plate contain unsecured plastic parts that fall off and are easy to lose. Also, be careful in step 6 to not exert too much pressure, or you can break the plastic tracks. 1. Remove the Right Cover (page 7-6). 2. Remove the Left Cover (page 7-7). 3. Remove the Top Cover (page 7-10). 4. Open Tray 1. 5. Unhook only the bottom of the 2 springs connecting the Knock-Up Plate to the Pick-Up Rack. Note DO NOT unhook the top portion of the springs from the Pick-Up Rack.
s3600-032
6. To disengage the Knock-Up Plate from the Tray 1 (MPT) Assembly, flex the left and right tray links from the indented portion of the tracks.
7-14
Tray Link
s3600-033
7. Facing Tray 1, slide the tray to the left to release the 4 pivot points securing the Tray, then remove the Tray 1 Assembly from the printer. Replacement Note Follow these steps to ensure correct replacement of the tray: To attach the Tray 1 (MPT) assembly to the Knock-Up Plate: 1. Attach the left and right plastic tray links to the top portion of the KnockUp plate. 2. Attach the bottom portion of the Knock-Up Plate to the plastic mounting links on the chassis. 3. Slide the assembly onto the four pivot points. 4. Insert the top portion of the secured tray links through the Knock-Up Plate indentations on the track.
7-15
s3600-034
7-16
7-17
Caution
s3600-036
Replacement Note When reinstalling, be sure to secure the Pick-up Rack in the boss on each side of the rack.
7-18
Retard Assembly
s3600-037
Replacement Note When reassembling, insert the Retard Roller over the left end of the retard shaft until the roller snaps in place.
s3600-009
7-19
Caution
Be careful not to break the MP actuator flag. Also, do not lose the spring located underneath the Friction Pad of the separator.
s3600-039
Replacement Note Before installing the three screws, be sure to snug the spring between the friction pad and the plastic base.
7-20
Caution
When removing the plastic cover in the step 5, lift the edge nearest the sensor first then the other end, being careful not to bend the actuator. 1. Remove the Tray 1 (MPT) Assembly (page 7-14). 2. Remove the 6 screws from the HVPS board to expose the connectors. 3. Disconnect CN3 from the HVPS board. 4. Unlace the 3-wire harness of CN3 from the HVPS. 5. Remove the plastic cover covering the sensor. 6. Gently push the plastic hook away from the sensor board to remove the board and sensor.
Hook
s3600-111
7-21
s3600-094
7-22
s3600-088
7-23
Springs
s3600-069
7-24
s3600-095
7-25
Service Parts Disassembly 8. Remove 1 screw, on the right end of the shaft, securing the bracket, remove the bracket with the bearing.
Bracket
7-26
Service Parts Disassembly 10. Lift the latch on the idle cam and slide the shaft to the right through the cam to free it from the printer.
Idle-Cam
s3600-042
7-27
Caution
Do not break the pick shaft by trying to force the Pick Roller off. 1. Slide the idle gears outward. Release the locking tab on the Pick Roller Assembly and slide the roller to the right.
Idle
s3600-043
7-28
s3600-044
7-29
1
s3600-045
9. Before you can slide the Pick-Up Camshaft in the next step, you must first release the white locking mechanism from the white plastic bearing, then lift free from the shaft. 10. Remove the Pick-Up Roller by lifting the black tab to slide it off the shaft.
7-30
s3500-046
11. Remove the black locking tab to free and remove the purple gear on the Retard Shaft. 12. Press the plastic release tab on the Retard Roller to remove the roller. 13. Remove 4 screws securing the Pick-Up Assembly and maneuver the pick assembly out of the printer. 14. Remove the Front Bottom Cross Bar secured by 2 screws and the ground strap.
7-31
s3600-047
Replacement Note When you are replacing the Cross Bar, place the ground strap between the bar and the printer before you insert the screw. Note Remove a small support metal bracket and screw separately from the main feeder assembly while removing the 4 securing screws. Also, remove a rubber spacing block held in place by the metal support bracket.
7-32
s3600-088
15. Release the plastic tab on the actuator that is mounted on the metal plate. Once the screw is out just lift it free from the boss. 16. Remove the 4 screws securing the pick assembly and maneuver the pick assembly out of the printer.
s3600-048
7-33
7-34
Latch
s3600-105
Latch
s3600-106
7-35
s3600-107
7-36
s3600-089
7-37
Caution
When removing screw #3 in step 3, make sure you do not bend or break the wire connected to the varistor. Also, screw #4 has a grounding strap that must be replaced during reassembly. 1. Remove the Right Cover (page 7-6). 2. Disconnect the CN1 cable on the Main Drive assembly. The other end is attached to the Main Board at CN19 DC Motor. 3. Remove all 6 screws in order. The screw numbers are labeled on the main assembly plate. 4. Remove the Main Drive Assembly.
Caution
3 6 5 4 2
s3600-050
7-38
Replacement Procedure
When reassembling: 1. Line up the metal shaft of the main drive assembly to the correct hole. 2. If necessary, lubricate the gears with Xerox Plastislip grease lubricant (PN-043E00550). 3. Install screws in order on the etched plate when replacing the Main Drive.
Caution
s3600-051
7-39
s3600-052
7-40
Gear Cap
s3600-053
6. Remove the 4 screws securing the Registration Assembly to the printer. 7. Remove the Registration Assembly from the printer.
7-41
s3600-054
7-42
Caution
Do not touch the surface of the Transfer Roller. 1. Open the Top Cover (page 7-10). 2. Remove the Print Cartridge and protect it from exposure to light. 3. Locate the cap on the left side of the Transfer Roller. 4. Use small needlenose pliers to depress one end of the cap and remove from the roller. 5. Pull the tab of the bearing clips on both ends of the Transfer Roller toward you to release roller tension. 6. Slide the roller slightly to the right so the end of the shaft clears the lip on the printer case and lift the Transfer Roller and the Bearing Clips from the printer.
Caution
Be careful not to drop the separate springs, copper contact, and plastic parts into the chassis.
7-43
Caution
When you remove the Exit Rollers, do not lose the springs.
s3600-057
Bearing
Exit Gear
s3600-058
7-44
s3600-059
7-45
s3600-090
7-46
Holder
s3600-060
7-47
s3600-056
7-48
Frame Assembly
Feed Idle Unit (PL 1.3.50)
1. Remove the Tray 1 (MPT) Assembly (page 7-14). 2. Remove the Retard Assembly (page 7-19). 3. Remove the Tray 1 Separator (Holder) Pad Assembly (page 7-20). 4. Remove 4 screws, 2 for each of the Feed Idle Units. 5. Remove each Feed Idle Unit.
s3600-061
7-49
PTL PBA
s3600-062
7-50
s3600-063
Replacement Note Reassemble the 4 screws in order of the numbers etched in the metal plates of the Developer Drive Assembly.
7-51
s3600-064
Replacement Note Be sure to insert the board in the securing slot before re-installing the board. Secure with the single screw.
7-52
s3600-075
Replacement Note Do not lose the copper mounting shield that connects the assembly to the chassis.
7-53
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Rear Cover (page 7-8). 2. Pull the locking lever and take out the Fuser Assembly. Note Press the two green tabs towards the center of the machine to pull out the Fuser.
Thermistor Connector
s3600-065
Replacement Note When you replace the Fuser, run the Clean Fuser cycle from the Control Panel (page 6-4).
7-54
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Left Cover (page 7-7). 2. Remove the Rear Cover (page 7-8). 3. Follow the instructions for removing the SMPS Power Supply (page 7-76). 4. Disconnect the connector from CON5 of the SMPS Power Supply. 5. From the bottom of the printer, remove the screws holding the sensor to the chassis. 6. Remove the Fuser Interlock Switch and wire harness.
s3600-102
7-55
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Left Cover (page 7-7). 2. Remove the Rear Cover (page 7-8). 3. Pull the locking lever and take out the Fuser Assembly. Note Press the two green tabs towards the center of the machine to pull out the Fuser. 4. From the left side of the printer, disconnect CN24 from the Main Board. 5. Free the CN24 harness and carefully pull into the interior of the printer. 6. Follow the instructions for removing the SMPS Power Supply (page 7-76). 7. From the bottom of the printer, remove a single screw holding the sensor to the chassis. 8. Remove the Fuser Exit Sensor and wire harness.
s3600-103
7-56
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Fuser Assembly from the Printer (page 7-54). 2. Remove two screws (6mm) securing the Thermostat to the Fuser assembly. 3. Slide one wire connector off each end of the Thermostat tabs.
s3600-115
4. Pull the Thermostat free from the Fuser Assembly. Replacement Note Be sure to insert the Thermostat with the Foil side near the edge of the Assembly.
7-57
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Fuser Assembly from the Printer (page 7-54). 2. Remove two screws from the Fuser assembly (see inset below).
s3600-114
7-58
Service Parts Disassembly 3. Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller.
s3600-124
4. Disconnect the 4-wire Thermistor plug from the Fuser Connector. 5. Remove one screw holding each of the two Thermistors and remove both thermistors with plug wiring harness from the Fuser Assembly.
s3600-132
7-59
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Fuser Assembly from the Printer (page 7-54). 2. Remove two screws from the Fuser assembly (see inset below).
s3600-114
7-60
Service Parts Disassembly 3. Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller.
s3600-124
4. Facing the Fuser Connector, disconnect the single wire connector from the right tab of the Thermistor.
s3600-116
7-61
Service Parts Disassembly 5. Remove two screws (8mm) securing the Fuser connector to the Fuser Assembly.
s3600-119
s3600-117
7-62
Service Parts Disassembly 7. Loosen (but do not remove) two screws (6mm) securing the Heat Roller retaining plates on each side of the Heat Roller.
L
s3600-118
R
s3600-127
7-63
Service Parts Disassembly 8. Pull the retaining plates away from roller and lift the roller free from the assembly. Note Make sure you do not lose any of the Heat Roller claws.
s3600-125
9. Remove the bushing (and rubber sleeve) from the left side of the roller.
s3600-121
7-64
Service Parts Disassembly 10. .From the right side of the roller, remove the spring retaining clip securing the gear to the roller.
s3600-122
Caution
Caution
Be sure to seat the Heat Roller claws over the Heat Roller before securing the Heat Roller to the assembly.
s3600-126
7-65
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Fuser Assembly from the Printer (page 7-54). 2. Remove the Heat Roller and Bushing (page 7-60). 3. Slide the Dual-lamp free from the Heat Roller.
s3600-120
Caution
Do not touch the lamps when re-installing. Fingerprints can cause the lamps to burn out prematurely.
7-66
Warning
Be sure you turn off the Printer and let the Fuser cool for 5 minutes 1. Remove the Fuser Assembly from the Printer (page 7-54). 2. Remove two screws from the Fuser assembly (see inset below).
s3600-114
7-67
Service Parts Disassembly 3. Unfold the Fuser Assembly to expose the Heat Roller and the Pressure Roller.
s3600-124
4. Facing the Fuser Connector, disconnect the single wire connector from the right tab of the Thermistor. 5. Remove two screws (8mm) securing the Fuser connector to the Fuser Assembly. 6. Remove one screw from each end of the Pressure Roller.
s3600-128
7-68
7. Slide the retaining plate and bushing off of each end of the Pressure Roller. 8. Lift the Pressure Roller free from the assembly.
s3600-130
Replacement Note Slide the retaining plates with bushings onto the Roller and seat into the plastic retainers before securing the two end screws.
7-69
s3600-091
5. Disconnect the LSU cable connector from CN10 on the Main Board. 6. Remove the 3 screws (8mm) securing the LSU to the chassis and remove the LSU from the printer.
7-70
s3600-066
Replacement Note The screws are numbered and need to be replaced and tightened in the correct order.
7-71
s3600-067
7-72
Stopper
s3600-068
7-73
Cover Open
s3600-070
7-74
Power Supplies
High Voltage Power Supply (HVPS) (PL 1.1.29.1)
Note Do not lose the three board-retaining springs when removing the HVPS. 1. Remove the Left Cover (page 7-7). 2. Remove the Rear Cover (page 7-8).
s3600-092
3. Remove 6 screws from the HVPS. 4. Disconnect all connectors from the HVPS. 5. Remove the HVPS from the printer. Replacement Note After reinstalling the SMPS board, make sure the actuator from the chassis can move freely into the Paper Tray Empty Sensor.
7-75
s3600-072
10. Remove 5 screws from the SMPS Power Supply Board. 11. Remove one grounding screw from the rear of the power supply. 12. Remove the SMPS Power Supply Board from the printer.
Caution
Since the fuser wire is hardwired to the SMPS Power Supply Board, disconnect the wire from the fuser side.
7-76
s3600-073
7-77
7-78
Parts List
In this chapter...
Serial Number Format Using the Parts List PL 1.1 Main Assembly PL 1.2 Cover Assembly PL 1.3 Frame Assembly (1 of 2) PL 1.3 Frame Assembly (2 of 2) PL 1.4 Fuser Assembly PL 2.1 Tray 2 Cassette PL 2.2 Tray 3 Cassette PL 2.3 Duplex Assembly
Chapter
Parts List
Component's part number Product type or model number Serial Number of the printer
The serial number is found on a label located on the frame of the printer. Front Cover must be opened to locate the Serial Number. The nine-digit serial number has the following format: PPPRSSSSS PPP = Three digit alphanumeric product code R = Single digit numeric revision digit, 0~9. To be rolled when a major product change occurs and initiated with a change request. Product Code MLB MKA MHB MHX Product 3600_B, 110 V Engine 3600V_B, 220 V Engine 3600_N, 110 V Engine 3600V_N, 220 V Engine
Mass Production Units (MP Build) PPP1SSSSS SSSSS = Five digit numeric serial number based on the following table: Product 3600_B, 110 V Engine 3600V_B, 220 V Engine 3600_N, 110 V Engine 3600V_N, 220 V Engine Starting Serial Number 804501 836501 843501 908501 Ending Serial Number 836500 843500 908500 995500
Example
MLB1804599: Xerox Serial Number MLB: Product Code for the Phaser 3600, configuration B, 110V printer 1 = Revision Level 804599 = Serial Number for 3600_B Serial Number Format
8-2
Parts List
Phaser 3600_N
Xerox Corporation Manufactured: JUNE 2008
s3600-110
8-3
Parts List
Identifier C E KL S
8-4
Parts List
8-5
Parts List
37 10 12 14 8
8-1 8-2 8-3 8-4
7
9-1 9-2 9-3
3
3-4 3-3 3-5 3-2 3-1
13 31 32 39 34 41
15
38 16
3-6
17 35 1 25 26 21 24 18
19
20-120-3
5 20
6
4-2
29
27
21-3 21-2 21-1
20-2
22 23 4
4-1
28
30 36 30
s3600-011
8-6
Parts List PL 1.1 Main Assembly Parts List Table ID No. 1 2 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 5 6 7 8 8.1 8.2 8.3 8.4 9 9.1 9.2 9.3 10 11 12 13 14 15 16 17 18 19 20 20.1 20.2 20.3 21 ELA UNIT REGI (Registration Assembly) GEAR REGI Z25 CAP M GEAR UNIT LSU (Laser Scan Unit) ELA UNIT EXIT SOLENOID ELA UNIT DEVE MOTOR ELA UNIT MAIN MOTOR PBA MAIN (Base) PBA MAIN (Network) MEA UNIT GEAR PICK UP GEAR M PICK UP CAM GEAR M PICK UP SPRINT ETC CAM MP MEA UNIT GEAR P/UP MP CARDINAL (Feed Unit 2) 007N01600 146N00131 007N01360 007N01599 122N00276 121N01100 127N07389 127N07571 140N63317 140N63333 007N01598 Name/Description ELA UNIT FRAME BASE ELA HOU BASE HOUSING MEA UNIT KNOCK UP MP (Tray 1 Knock-Up Plate) 050N00475 PLATE M KNOCK UP MP MPR PAD KNOCK UP MP PMO SIDE GUIDE MP R PMO SIDE GUIDE MP L GEAR PINION SHAFT REINFORCEMENT MEA UNIT COVER MP XRX (Transfer Roller) COVER M MP XRX TRAY M EXTND MP TRAY M LINK MP L TRAY M LINK MP R ROLLER TRANSFER ELA UNIT HOLDER TR R PMO BUSHING TR SPRING ETC TR R HAWK PMO TRANSFER HOLDER IPR PLATE TR ELA UNIT HOLDER TR L PMO BUSHING TR SPRING ETC TR R HAWK PMO TRANSFER HOLDER PMO CAP TR 021N02248 019E63480 012N00521 012N00522 022N02353 030N00560 002N02410 Part Number
8-7
Parts List PL 1.1 Main Assembly Parts List Table (continued) ID No. 21.1 21.2 21.3 22 23 25 26 27 28 29 30 31 32 34 Name/Description GEAR MP HOLDER CAM GEAR MP PICK UP SPRING ETC CAM MP BEARING PICK UP BRACKET P SHAFT MP SOLENOID MAIN SOLENOID MP (Tray 1 (MPT) Pick Solenoid) RING E SHIELD P SMPS SMPS V1- 110V SMPS V2- 220V BAR P CROSS BOTTOM (Front Bottom Cross Bar) FAN DC (Left Side Cooling Fan) STOPPER M FAN80 ELA UNIT DEVE (Print Cartridge) 7K Toner Cartridge 14K Toner Cartridge ELA UNIT CASSETTE (Tray 2) ELA UNIT SCF (Optional Tray 3) ELA UNIT DUPLEX BRACKET P DUMMY CTRL HVPS BRACKET NIC PBA SUB (NIC BOARD) STOPPER M NETWORK 40MM FAN 127N07568 105N02145 106R01370 106R01371 109R00756 097N01673 097N01679 127N07569 105N02144 105N02146 121N01167 121N01102 Part Number
35 36 37 38 39 39.1 39.2 40 41
8-8
Parts List
8-9
Parts List
1-1
1-8
1-5
1
1-2
1-X
6-10 6-1
6-9
6
6-3
3 5
s3600-012
8-10
Parts List PL 1.2 Cover Assembly Parts List Table ID No. 1 (1-X) 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 2 3 4 5 6 6.1 6.2 6.3 6.4 6.5 6.7 6.8 6.9 6.10 7 8 Name/Description AS UNIT COVER TOP COVER M TOP COVER M OPEN XRX PMO STACKER RX LEVER M STACKING 38 STOPPER M HINGE OPEN COVER M OP PANEL XRX SHEET OVERLAY BUTTON MEC BRUSH ANTISTATIC PBA SUB PANEL BD KEY M BUTTON XRX KEY M CANCEL CAP M LED XRX WINDOW M LCD COVER M LEFT COVER M RIGHT COVER M CONTROL BOX COVER M FRONT INNER MEA UNIT COVER REAR COVER M REAR PMO STACKER REAR ICT BRKT REAR COVER GUIDE M EXIT PMO STRIPE PEX ROLLER F/UP(2) SPRING ETC SEPARATION LABEL(P) JAM REMOVAL FAN CO VER M FRAME EXIT COVER M DUMMY DUP (FILLER PANEL) 127N07569 002N02417 002N02420 001N00462 002N02413 002N02414 002N02419 002N02415 002N02416 140N63320 Part Number 002N02411 002N02730 002N02729 002N02418 036N00030
8-11
8-12
Parts List
12
11-2 11-2 11-1
43 8 0 22 20 16
5-4
6 10 43 13 9 23 27 5
11 12
21 19
5-3 5-2 5-1
17 18 15 18 17 25 29 30
4-3 4-4 4-2 4-5 4-6 14-1 14-3
24 26 36 37 38 28
45
14
14-2
1 40 39 41 43 2
2-2 2-4-2 2-4 2-4-3 2-4-1 2-2 2-1 2-5
4-1
4-7 4-8
42
33 35 39 44 34
32 31 3
3-5
3-4 3-1
s3600-013
Parts List
48 99 81 98 88 87 84 85 89 92 90 86 83 82 100 83 79 77 76 78 80
48-6
47
47-2 47-3 47-4 47-1 47-5
91
93 94 96
70
71 72
49
49-5 49-3 49-2 49-4 49-8
97
95 49 50
50-4 50-3
69 66 41 50
50-6 50-9 50-6 50-5 50-150-7 50-2
73 68
65 61 63 62
67
51
53 58
54 52 60
60-4 60-5
64
59-11 59-7 59-5-2 59-5-1 59-4 59-5 59-9 59-6 59-10 59-8
60-6-1 60-6-2
59
59-2-1
60-2 60-3
59-2-2 59-2-3
59-1
59-3 59-2
55 56 57
s3600-014
8-13
Parts List
PL 1.3 Frame Assembly Parts List Table Item No. 1 2 2-1 2-2 2-4 2-4-1 2-4-2 2-4-3 2-5 3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 4 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 5 5-1 5-2 5-3 5-4 6 7 8 9 PMO ACTUATOR OUT FULL (Outbin Full Actuator) GEAR M EXIT Z17 120N00479 007N01364 Description FRAME M BASE MEA UNIT PICK UP MP (Tray 1 Pick-Up Rack) SHAFT M PICK UP MP PMO IDLE PICK UP MP ELA UNIT ROLLER P/UP MP HOLDER M PICKUP MP HOUSING M PICK UP MP RUBBER PICK UP MP CAM M SHAFT MEA UNIT GEAR IDLE BRACKET P GEAR IDLE GEAR FUSER IDLE 3 GEAR M FUSER IDLE 2 GEAR M FUSER DRV IN CLUTH M HUB GEAR RDCN FUSER OUT RING-E ELA HOU BASE HOLDER (Separator Pad Assembly) FRAME M HOLDER PAD HOLDER M PAD RPR FRICTION PAD MP SPRING ETC PAD PMO ACTUATOR EMPTY MP SPRING ETC EMPTY PHOTO INTERRUPTER CBF HARNESS MP EMPTY MEA RACK EXIT ROLLER PMO HOLDER EXIT ROLL PMO ROLLER FD F PMO ROLLER FD R SPRING EXIT ROLL FD ROLLER EXIT F/DOWN 006N01264 022N02081 022N02173 007N01362 022N02182 130N01536 Part Number
8-14
Parts List PL 1.3 Frame Assembly Parts List Table (continued) Item No. 10 11 11-1 11-2 12 13 14 14-1 14-2 14-3 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Description HOLDER BUSHING EXIT (F/DOWN) MEA UNIT ROLL EXIT DUPLEX (Duplex Roller) SHAFT M EXIT DUPLEX RMO RUBBER EXIT DUP BUSH M EXIT D7 GEAR M EXIT DUP Z21 ELA HOU CST SENSOR (Paper Size Sensor) PBA SUB CASSETTE IPR PLATE SENSOR IPR BRACKET SENSOR CBF HARNESS PSIZE GUIDE P REGI UPPER SPRING ETC LEVER HOLDER M BUSHING TX GUIDE PLATE PAPER IPR P GROUND PLATE PAPER PHOTO INTERRUPTER (Outbin Full Sensor) CBF HARNESS THERM PMO HOUSING TERMINAL IPR TERMINAL FU CBF HARNESS FUSER CAP M HOUS TERM SHIELD P CTRL GROUND P MOTOR DEVE GROUND P GUIDE TR GROUND P REGI ROLLER GROUND P PICK UP MP GROUND P SCF MAIN GROUND P MOTOR MAIN GROUND P GUIDE DUP CAP M GUIDE HARNESS PMO DUMMY DEVE ELA HOU VARISTOR FOOT ML80 PMO REMOVE LOCK CST 130N01274 013N13839 007N01363 130N01461 Part Number 013E25770 006N01265
8-15
Parts List PL 1.3 Frame Assembly Parts List Table (continued) Item No. 41 42 43 44 45 47 47-1 47-2 47-3 47-4 47-5 48 48-1 48-2 48-3 48-4 48-5 48-6 48-7 48-8 49 49-1 49-2 49-3 49-4 49-5 49-6 49-7 49-8 49-9 49-10 49-11 50 50-1 50-2 MEA UNIT FRAME LSU LOW (Sub-toner Low Sensor) FRAME M LSU LOWER (LSU Lower Cover) PBA TONER SENSOR TERMINAL P DEVE PBA SUB COVER OPEN CAP M COVER OPEN ELA UNIT FEED 3X5 HOLDER M SAW GUIDE P TRANSFER FRONT PLATE P SAW SHAFT M ROLLER BELT ROLLER M IDLE BELT IEX SHAFT IDLE, F/UP RUBBER BELT FEED GUIDE M SHAFT BELT ELA UNIT ROLLER IDLE FRAME M RETARD HOLDER M RETARD SPRING ETC PAD BUSH M RETARD 2 HOUSING M RETARD SHAFT RETARD RING-E PMO HUB OUT RETARD SPRING TS PMO HUB IN RETARD RUBBER RETARD ELA UNIT FEED2 IDLE (Feed 2 Idle Unit) HOLDER IDLE FEED2 CAP M IDLE FEED2 022N02176 022N02349 130N01399 002N02729 022N02174 001N00500 Description SHAFT M GEAR RETARD SHAFT M COUPLING RETARD PMO BEARING SHAFT GEAR REGI Z25 013N13841 Part Number
8-16
Parts List PL 1.3 Frame Assembly Parts List Table (continued) Item No. 50-3 50-4 50-5 50-6 50-7 50-9 51 52 53 54 55 56 57 58 59 59-1 59-2 59-2-1 59-2-3 59-3 59-4 59-5 59-5-1 59-5-2 59-6 59-7 59-8 59-9 59-10 60 60-1 60-2 60-3 60-4 60-5 Description SPRING ETC PAD BUSH M RETARD SHAFT IDLE FEED2 RING-E ROLLER M IDLE FEED2 SHAFT HUB IN STOPPER M KNOCK UP MP L STOPPER M KNOCK UP MP R RAIL M LEFT DUPLEX RAIL M RIGHT DUPLEX PMO BEARING SHAFT GEAR REGI E25 BEARING PICK UP PMO ACTUATOR EMPTY (Paper Tray Empty Actuator) ELA UNIT PICK UP SHAFT PICK UP MEA UNIT P/UP HOUSING (Pick Roller) PMO M IDLE PICK UP RUBBER PICK UP PMO M CAM PICKUP SHAFT FEED 1 AS FEED 1 ROLL ASSY HOUSING M FEED1 RUBBER FEED1 GROUND P PICK UP MAIN BEARING PICK UP PMO BUSHING FEED GUIDE P FRONT DUP PICKUP GUIDE M SUPPORT PICKUP ELA UNIT FEED2 FRAME M PICK UP PMO BUSHING FEED SHAFT M FEED2 BEARING PICK UP RUBBER ROLLER FEED2 022N02178 022N02187 022N02177 120N00519 022N02183 032N00441 032N00442 013N13841 Part Number
8-17
Parts List PL 1.3 Frame Assembly Parts List Table (continued) Item No. 61 62 63 64 65 66 67 68 69 71 72 73 74 76 77 78 79 80 81 82 83 84 86 87 88 89 90 91 92 93 94 95 96 97 98 PBA SUB EXIT SENSOR (Fuser Exit Sensor) PBA FUSER SW (Fuser Interlock Switch) GUIDE M FRONT TERMINAL P GUIDE FRONT ELA UNIT FUSER 110V ELA UNIT FUSER 220V PMO GUIDE DEVE L PMO GUIDE DEVE R SPRING ETC GUIDE DEVE TERMINAL P TR KESTREL TERMINAL SPRING TR PBA MAIN ZENER CBF HARNESS EARTH GROUND P ZENER GROUND P FUSER TERMINAL P HV CARDINAL MEA UNIT TERMINAL TR CBF HARNESS HVPS IPR P GROUND OPC PBA SUB EMPTY SENSOR (Paper Tray Empty Sensor) CBF HARNESS SENSOR PBA SUB FEED SENSOR (Tray 1 FeedSensor) CAP M HV 140N63024 140N63023 126N00293 126N00294 130N01400 130N01401 Description PBA SUB JOINT (Joint Card) CBF HARNESS TRAY OUT CAP M POWER CBF HARNESS INLET SHAFT M BELT GEAR PMO BEARING SHAFT GEAR M EXIT Z17 CAP M DEVE MOTOR CBF HARNESS DUPLEX CAP M WIRE PTL LOWER TERMINAL P PTL CBF HARNESS PTL 021N02249 116N00243 152N11756 Part Number 140N63022
8-18
Parts List
8-19
Parts List
2 5 3 4
4 6
1 7 10 34 2 60 24 44 27 55 56 57 48 49 46 45 58 47 50 52 64 47 48 65 49 50 51 52 51 61 62 54 63 46 42 43 45 53 24 22 44 23 26 36 35 31 28 8 29 28 33 32 27 37 38 39 40 41 30 9 2 8 8 28 33 32 31 27 25 26 27 29 28 28 17 14 2 18 19 20 21 16 15 13 12 7 11
45 2
66
59 s3600-015
8-20
Parts List
PL 1.4 Fuser Assembly Parts List Table Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 31 32 33 34 35 Description ELA UNIT FUSER (110V) ELA UNIT FUSER (220V) SCREW-TAPTITE THERMOSTAT SCREW-TAPTITE HARNESS-FUSER COVER-FUSER UP LAMP PMO BUSHING TX HOLDER -IDLE ROLLER SPRING ETC ACTUATOR PMO ROLLER UPPER DP PMO ACTUATOR EXIT GEAR-EXIT HOLDER REAR LEVER LABEL HOLD-REOPEN ROLLER EXIT F_UP PLATE ACTUATOR COVER HOLDER-LEVEL R GEAR IDLE CAP ACTUATOR GREASE-BEARING RING E GEAR-FUSER 2 LAMP BRACKET LAMP-RIGHT BEARING BALL BRACKET FUSER-LAMP RING CS SPRING ETC-SEPARATION GUIDE-CLAW POLY COVER SLIDE SENSOR TEX-SHAFT IDLE F/UP PEX ROLLERF/UP SPRING-TS HOLDER-LEVER L GROUND FUSER BRUSH 130N01537 Part Number 126N00293 126N00294
8-21
Parts List PL 1.4 Fuser Assembly Parts List Table (continued) Item No. 36 37 38 39 40 41 42 43 44 48 49 50 52 53 54 55 56 57 58 59 60 61 63 64 65 66 Description LEVER AUTO RELEASE L TUBE SMALL TUBE MIDDLE RING E THERMISTOR TUBE LARGE SPRING ETC LOCK LEVER AUTO RELEASE R BUSHING-HEAT_ROLLER BEARING BALL CAP FUSER LOCK BUSHING PRESSURE_ROLLER HOLDER PR SHAFT HEAT ROLLER BRACKET DRAWER MEC-BRUSH ANTISTATIC LAMP-DUAL 266 (110V) LAMP-DUAL 266 (220V) GROUND HR LAMP SPRING CS COVER FUSER LO LAMP BRACKET LAMP-LEFT CAP ACTUATOR SPRING ETC GUIDE FELT CLEAN TONER GUIDE REAR LAMP PRESSURE ROLLER 022N02352 122N00277 122N00278 022N02351 013N13884 013N13883 130N01462 Part Number
8-22
Parts List
8-23
Parts List
9 17 10
13
15 14 11
16
20-3 20-2
20-4 20-1
20 27
21 19 25 26
12
18 4 2 1 3 5
s3600-016
8-24
Parts List
ELA UNIT CASSETTE FRAME M CASSETTE GUIDE M HANDLE INDICATOR EMPTY PLATE P KNOCK UP SPRING PLAT K/UP GEAR PINION CAP M GUIDE SIDE L GUIDE P SIDE L GUIDE M SIDE LOCK GUIDE P SIDE R GUIDE M REAR GUIDE P REAR PAPER SPRING ETC GUIDE PAPER GUIDE M LOCK GUIDE M REAR GUIDE M EXTENTION BRACKET P EXTENTION GUIDE M PAPER HOLDER M PAD HOUSING MEA UNIT HOLDER PAD HOLDER M PAD SHEET HOLDER PAD R2 RPR FRICTION PAD IPR PLATE PAD SPRING EXIT ROLL FD PMO LOCKER PLATE SPRING LOCKER PLATE GUIDE M PAPER SIZE
109R00756
019N00947
8-25
8-26
Parts List
4 29 41 30 33
3 28 38
38-2
43
27 35 42 26 1 40 35 25 16 16 35 16 14 21 32 31 16 20 17 20 14
11-1 11-2
37
34-1 34-3 34-1
38-1
36 34
34-2
6 5 10 7 11 8 9
22
15 16 13 18 14 19
12
11-5 11-3 11-4
s3600-017
Parts List
PL 2.2 Tray 3 Cassette Parts List Table Item No. 0 1 2 3 4 5 6 8 9 10 11 11-1 11-2 11-3 11-4 11-5 12 13 14 15 16 17 18 19 20 21 22 23 24 25 27 28 29 30 31 SHAFT PICK UP SCF PBA SCF COVER OPEN ELA HOU CST SENSOR PHOTO INTERRUPTER PMO ACTUATOR EMPTY, SCF GEAR SCF PICK UP CAM 120N00520 007N01366 140N63025 Description ELA UNIT SCF (Tray 3, 500-sheet feeder) FRAME M SCF COVER M RIGHT SCF COVER M LEFT SCF COVER M DUMMY SCF PBA SCF CBF HARNESS OPE BUSH CABLE CBF HARNESS SCF INTERFACE SOLENOID MAIN ELA UNIT MOTOR SCF BRACKET P SCF MOTOR MOTOR STEP 7.5 DEG GEAR M SCF RDCN RETARD GEAR M SCF RDCN FEED GEAR M SCF RDCN PICK UP CBF HARNESS OPE IPR GROUND SPRING FEED PMO BEARING SHAFT MEP CLUTCH FEED SCF RING E SHAFT M COUPLING RETARD S SHAFT M GEAR RETARD GEAR REGI Z25 BAR P CROSS BOTTOM PMO REMOVE LOCK CST ELA UNIT IDLE SCF 022N02350 127N07570 152N11714 140N63300 Part Number 097N01673
8-27
Parts List PL 2.2 Tray 3 Cassette Parts List Table (continued) Item No. 32 33 34 34-1 34-2 34-3 35 36 37 38 39 40 41 42 43 Description FOOT ML80 IPR GROUND TOP MEA UNIT PICK UP HOU PMO M IDLE PICK UP RUBBER PICK UP HOUSING M PICK UP PMO BUSHING FEED PMO M DUMMY SHAFT SPRING ES HOUSING M FEED1 RUBBER FEED1 CBF HARNESS MOTOR CBF HARNESS SCF EMPTY CBF HARNESS SCF CASSETTE CBF HARNESS SCF P SIZE Part Number
8-28
Parts List
8-29
Parts List
25 26 26 24 33 27 32 30 4
16 8 10 9 7 6 11 34 30
28 29 28 31
1 17 18 19 20 21 22 13 12 5
14 15 23
s3600-018
8-30
Parts List
PL 2.3 Duplex Assembly Parts List Table Item No. 0 1 2 3 4 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Description ELA UNIT DUPLEX FRAME M DUPLEX GUIDE M UPPER DUP COVER M REAR DUP MEA ETC ALIGN DUP GUIDE M ALIGN DUP SHAFT IDLE ROLL DUP ROLLER M IDLE DUP PCT SLIP WASHER SPRING ETC DUP PULLEY M 18 DUMMY DUP PULLEY 18 DUP BUSH M FEED DUP BELT TIMMING ROLLER FEED DUP RING C CAP M CONNECTOR DUP DUCT M FAN DUP FAN DC HAWK PBA SUB DPX SCF CABLE CLAMP IPR TERMINAL GND DUP LOCKER M DUP SHEET FRAME DUP SPRING TS PMO ACTUATOR FEED DUP PBA SUB MP SEN (Duplex Exit sensor) CBF HARNESS POWER GND MOTOR STEP BRACKET P MOTOR DUP PULLEY M 30 DUP BELT TIMING GEAR PULLEY M 30 DUMMY DUP RING E CBF HARNESS D JOINT Part Number 097N01679
8-31
Parts List
8-32
Chapter
The P/J column lists the Plug/Jack or CN numbers in numerical order. The Map column provides the map number of the specific areas (i.e., Electrical, Laser Scan Unit...etc.) The Coordinates column lists the diagram coordinates for the location of the connector. The Remarks column provides a brief description of each connection.
1. Locate the P/J connector designator in the first column of the table. 2. With this information, go to the map listed in the second column. 3. Use the coordinates to locate the connection indicated on the map with its P/J designation number.
9-2
Print Engine Plug/Jack Designator Table Map P/J 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 P/J1 CN3 CN4 CN6 P/J9 P/J11 P/J12 P/J14 P/J16 P/J17 P/J18 P/J19 P/J20 P/J21 P/J22 P/J23 P/J24 P/J25 P/J26 P/J1 P/J2 P/J3 P/J4 P/J5 P/J6 P/J1 P/J2 P/J3 MP/J2 Coordinates Remarks H-143 J-139 I-134 H-134 F-134 E-134 D-134 F-142 C-134 C-138 C-139 C-136 B-135 B-136 B-137 B-139 B-140 B-141 D-134 A-140 A-141 D-141 J-141 H-141 J-140 J-134 K-136 J-139 J-140 Connects the Laser Scan Unit to CN10 of the Main Board. Connects the Ethernet to the Main Board. Connects the USB to the Main Board. Connects the Serial port to the Main Board. Connects Main Board to the Thermistor. Connects the main board to the Duplex Solenoid Connects the Main Board to the 1st RAM DIMM. Connects the Main Board to the 2nd RAM DIMM. Connects the Main Board to the Control Panel Connects the Main Board to the Duplex Board. Connects the Main Board to the Main Motor. Connects the Main Board to CON4 of the SMPS Board. Connects the Main Board to the Developer Motor. Connects the Main Board to the PTL Board. Connects the Main Board to CON3 of the SMPS Board. Connects the Main Board to P/J5 of the Exit Sensor. Connects the Main Board to CN12 of the Joint Board. Connects the Main Board to he Optional Tray 3. Connects the Main Board to the Rear Fan. Connects the SMPS Board to the AC inlet. Connects the SMPS Board to the Fuser. Connects the SMPS Board to CN23 of the Main Board. Connects the SMPS Board to CN20 of the Main Board. Connects the SMPS Board to the Jam Cover Switch. Connects the SMPS Board to CN1 of the HVPS Board. Connects the HVPS Board to CON6 of the SMPS Board. Connects the HVPS Board to CN2 of the Toner Sensor Board. Connects the HVPS Board to the Feed Sensor. Connects the HVPS Board to the Tray Empty Sensor.
9-3
A 131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
s3600-101
9-4
A 131
132
133
CN9 CN8
CN6 CN4
134
135
136
CN1
137
138
139
CN23
140
CN3
CN24
141
CN25
142
CN14
143
CN12
144
145
s3600-096
9-5
A 131
132
133
134
135
136
137
138
139
140
141
142
CON02
143
CON01
CON03
CON06 CON05
CON04
144
145
s3600-097
9-6
A 131
132
133
FUSER
134
MHV OPC
THV
CN1
135
136
137
138
139
CN4 CN3
140
141
142
143
144
145
s3600-098
9-7
Wiring Diagrams
Notations Used in the Wiring Diagrams
The following table lists the symbols used in the wiring diagrams.
Symbol
Plug
Denotes a Jack.
Jack
P/Jxx YY
Plug and Jack
JPxxx
Denotes a Jumper Point (JPxxx/xxx). Each end of the Jumper connection has a numeric designation.
Jumper
Fuser PL X.Y.Z
Denotes the parts. PL X.Y.Z implies the item Z of plate (PL) X.Y in Parts List.
Subassembly 1
Heater
Subassembly 2
9-8
Symbol
Control
Subassembly 3
DEVE_A
Denotes a connection between parts with harness or wires, attached with signal name/ contents.
Connection Wire
CLUTCH ON(L)+24V
Denotes the function, and logic value of the signal to operate the function (Low: L, High: H). The given voltage is for signal in high status. The arrow indicates the direction of signal.
Function Logic 1
EXIT SENSED(L)+3.3VDC
Function Logic 2
Denotes the function, and logic value of the signal when the function is operated (Low: L, High: H). The given voltage is for signal in high status. The arrow indicates the direction of signal. Denotes a connection between wires.
Connection of Wires
Solenoid/Clutch
Denotes a Motor.
M
Motor
9-9
Symbol
Optic Sensor
Denotes an LED.
LED
On Off Switch
Temperature Switch
NPN Phototransistor
Interconnection, Differing
9-10
Symbol
Description Represents an interconnection between parts using a conductive part such as a Plate Spring.
Denotes DC voltage. Denotes signal ground. Denotes analog ground. Denotes return.
9-11
CN3
CN4 CN1
Thermistor Laser Unit Duplex Solenoid RAM DIMM RAM DIMM Main Motor Developer Motor PTL 2
TH1
CN8
Paper Full Sensor Paper Size Sensor SMPS (LVPS) Fan Main Fan
CN1 CN1 CN9 CN5 CN7 CN26 CN12 CN16 CN14 CN17 CN1 CN18 CON1 CN1 CN20 CN19 CN21 CON4 CON2 DUP1 CNT1
CN11
Erase Lamp
CN1
SMPS (LVPS)
P/J5 CN23
CON5
CN10 CN11
Joint Board
CN12 CN24 CN22 CON3
CON6
CN7
P/J3
Rear Fan
s3600-019
9-12
Main Board
CN19 1 2 3 4 5 6 7 8 9 10 11 12 13 14
CON4 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CON3 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
LVPS (SMPS)
CON1 1 2 CON2 1 2 3
AC Inlet
HOT NEUTRAL
Fuser
+24VDC CN22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 DEV_AC_PWM +24VDC DEV_AC_Vpp +24VDC DEV_AC_CON +24VDC DEV_VDC_PWM +24VDC FUSER_BIAS_PWM +3.3VDC MHV_PWM +3.3VDC MHV_READ +3.3VDC THV_PWM VCC THV_READ VCC nTHV_EN GND FUSER_COVER GND GND GND FUSER_ON GND GND GND CON6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CN1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
HVPS
+3.3VDC
s3600-024
HVPS +3.3VDC
CN3 1 2 3 CN4 1 2 3
+3.3VDC
s3600-025
9-13
CN6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
+24VDC P_SIZE3 FAN_SMPS P_SIZE2 FAN_MAIN P_SIZE1 THERM_IN TEMP_2 FUSER_ON OUTBIN_FULL CART_CLK P_REGI CART_DPUT/DIN P_EMPTY
CN6 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
CN2 1 2 3 4 5 6
CN2 6 5 4 3 2 1
HVPS
+3.3VDC CN3 1 2 3 CN4 1 2 3 4 CN1 1 2 +24VDC 3 CN5 1 2 3 +24VDC SIGNAL +24VDC SIGNAL +3.3VDC SIGNAL GND
PFULL Paper Full Sensor 3 2 1 PSIZE Paper Size Sensor 4 3 2 1 P/J2 3 2 1 P/J1 3 2 1 Main Fan SMPS Fan
+24VDC
+24VDC
CN26 1 2 3 4 5 6 7 8 9
CN1 9 8 7 6 5 4 3 2 1
s3600-022
9-14
Main Board
CN20 1 2 3 4 5 6 7
CN1 7 6 5 4 3 2 1 PTL2
Developer Motor
+5VDC 1 2 +3.3VDC
CN21
CN23 1 2 3
Exit Sensor
+24VDC
CN24 1 2 3 4 5 6 7 8 9 +24VDC MAIN_CLUTCH MP_CLUTCH REGI_CLUTCH MP_EMPTY +3.3VDC CASSETTE_DETECT GND TEMP_1
CN12 9 8 7 6 5 4 3 2 1
+24VDC
CONTROL +24VDC
Main Solenoid
CONTROL +24VDC
+3.3VDC
+3.3VDC
CN13 1 2 3
CN1
+24VDC +3.3VDC
CN25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
+24VDC +3.3VDC SCF_EMPTY SCF_RXD SCF_DETECT SCF_TXD GND GND GND GND GND
9-15
CN9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN11 1 2
GND LSU_5V LD_POWER2 LD_POWER1 VDO1_minus VDO1_plus VDO1_minus VDO1_plus nLD_EN1 nSH1 nSH2 nSH2 nHSYNC_minus LSU_CLK nREADY LSU_MOT_ON GND +24VDC
CN1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Laser Unit
+24VDC
+24VDC
PDX_SOL +24VDC
Duplex Solenoid
+24VDC
CN18 1 2 3 4 5 6 7 8 9 10
CN1 10 9 8 7 6 5 4 3 2 1
Main Motor
s3600-020
9-16
Main Board CN4 1 2 3 CN16 +24VDC 1 2 3 4 5 6 +3.3VDC PANEL_TXD PANEL_RXD nRSTOUT GND +24VDC SIGNAL P/J3 3 2 1 P/J4 1 2 3 CNT1 6 5 4 3 2 1 Control Panel Rear Fan
+3.3VDC +24VDC 1 2 3 4 5 6 7 8 9 CN17 +24VDC +3.3VDC +3.3VDC DUPLEX_RXD DUPLEX_DETECT MDUPLEX_RXD GND GND GND DUP1 9 8 7 6 5 4 3 2 1 s3600-023 Duplex Board
9-17
9-18
Reference
Contents...
Reference
Reference
Acronym
Description
3TM A3 A4 A5 AC AMPV APC ASIC ASSY ATM BCR BLDC BOOTP BSD BTM BTR CAM CCD CD CD CLT CN CON CRU CRUM CST CUPS dB DC
Three Tray Module Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches). Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches). Paper size 148 millimeters (5.82 inches) x 210 millimeters (2.10 inches). Alternating Current is type of current available at power source for the printer. Average Monthly Print Volume Auto Power Control Application Specific Integrated Circuit Assembly Adobe Type Manager Bias Charge Roller Brush-Less Direct Current Boot Parameter Protocol Block Schematic Diagram Bottom Bias Transfer Roller Cam Shaft Charged Coupled Device (Photoelectric Converter) Circuit Diagram Compact Disc Clutch Connector Connector Customer Replaceable Unit Customer Replaceable Unit Meter/Memory Cassette Common Unix Printing System Decibel Direct Current is type of power for printer components. Machine converts AC power from power source to DC power. Phaser 3600 Printer Service Manual
Ref-2
Reference
Acronym
Description
DCU DDR2 DIMM DEVE DHCP DIMM DPI DRV DUP Duplex EC ECM EEA EEC EEPROM EOM ESA ESD FCC FDR FE FPOT FR/FRNT FRU F/W GB GDI GND HARN HCF HDD HOU HUM HVPS Hz IC IDT
Diagnostic Control Unit Double Data Rate Dual In-Line Memory Module Developer Dynamic Host Configuration Protocol Dual In-line Memory Module Dot Per Inch Drive Duplex 2-sided printing European Community Error Correction Mode European Economic Area European Economic Community Electrically Erasable Programmable Read-Only Memory End of Message Electric Static Attachment Electrostatic Discharge. A transfer of charge between bodies at different electrostactic potential. Federal Communications Commission Feeder Field Engineer First Print Output Time Front Field Replaceable Unit Firmware Giga Byte Graphics Device Interface Ground Harness High-Capacity Feeder Hard Disk Drive Housing Humidity High-Voltage Power Supply Hertz (cycles per second) Integrated Circuit Intermediate Drum Transfer
Ref-3
Reference
Acronym
Description
IEC I/F IP IPM IPP IQ KB LAN LCD LD LED LEF LSU LTR LVPS MAC MB MHz MM MOT MPT NCS NCU NPP NVM NVRAM OHP OPC OPT OS PBA PC PCB PCL PDL P/J
International Electrotechnical Commission Interface Image Processor Image Per Minute Internet Printing Protocol Image Quality Kilo Byte Local Area Network Liquid Crystal Display Laser Diode Light Emitting Diode Long-Edge Feed Laser Scan Unit Letter Size Paper (8.5 x 11 inches) Low-Voltage Power Supply Media Access Control Mega Byte Mega Hertz Millimeters Motor Multi-Purpose Tray Non-Contact Sensor Network Control Unit No Paper Non-Volatile Memory Non-Volatile Random Access Memory Overhead Paper (Transparency) Organic Photo Conductor Optional Operating System Printed Board Assembly Personal Computer Printed Circuit Board Printer Command Language Page Description Language Plug Jack (electrical connections)
Ref-4
Reference
Acronym
Description
PJL PL PPD PPM PPR PPS PPS PS PTL PV PWB PWBA PWM RAM RH RLS ROM ROS SEF SMPS SNR SOL SOS SPOOL STS SYNC TDC THV TNR TRNS UI USB
Printer Job Language Parts List PostScript Printer Description Pages Per Minute Partial Page Request Pages Pulses Per Second PostScript Pre-transfer Lamp Print Volume Management Printed Wiring Board Printed Wiring Board Assembly Pulse Width Modulation Random Access Memory Relative Humidity Release Read-Only Memory Raster Output Scanner - Laser Scan Unit Short-Edge Feed Switching Mode Power Supply Sensor Solenoid Start of Scan Simultaneous Peripheral Operations Online Soft Touch Sensor Synchronous or Synchronization Toner Density Control Transfer High Voltage Toner Transport User Interface Universal Serial Bus
Ref-5
Reference
Ref-6
Index
A
Access Door, disassembly, 7-12 acronyms and abbreviations, A-2 Duplex Assembly, 2-9 disassembly, 7-37 Duplex paper path, 2-5 Duplex Roller, disassembly, 7-47 Duplex Unit Sensor, 2-16 parts list, 8-31 view of parts, 8-30 Duplex board to Main Board Wiring Diagram, 9-17
B
black print defects, 5-13 blank print defects, 5-9
E
ENERGY STAR, 1-ii error message list, 3-11 Exit Assembly Exit Gear, disassembly, 7-44 Exit Roller, disassembly, 7-44 Exit rollers, 2-5 Exit Solenoid, disassembly, 7-48
C
Center Loading Process, 2-7 charge roller, 2-2 cleaning, 2-2 Laser Scan Unit, 6-3 printer, 6-2 Cleaning blade, 2-3 Clutches/Solenoid tests, 3-9 Consumables, 1-3 contamination defects, 5-15 Control, 7-6 Control Panel components, 1-5 disassembly, 7-13 LED, 1-5 menu map, 1-5 messages, 1-5 Controller Unit to Main Board Wiring Diagram, 9-17 Cooling Supply Fan, disassembly, 7-73 coordinates column for designators, 9-2 Cover Assembly Cover Open Board and Sensor, 2-16 Cover Open Sensor, disassembly, 7-74 Cover status, 3-5 parts list, 8-11 view of parts, 8-10
F
faded image defects, 5-18 Fan tests, 3-9 fastener types Posi-Drive screw types, 7-4 precautions, 7-4 Feed Assembly Feed Roller, 2-5 Feed Sensor, 2-5 Idle Unit, disassembly, 7-49 process, 2-7 Frame Assembly parts list, 8-13 view of parts, 8-12 Functional specifications, 1-7 Fuser Assembly, 2-5, 2-8 defects, 5-3 disassembly, 7-54 Exit Sensor theory, 2-16 Fuser control tests, 3-9 Fuser Exit Sensor, disassembly, 7-56 Fuser Interlock Switch, disassembly, 7-55 parts list, 8-21 view of parts, 8-20
D
Developer Drive, disassembly, 7-51 Developing Motor, 2-7 Device control tests, 3-10 Diagnostic Menu Map, 3-5 Disassembly general notes, 7-2 notation, 7-5 Drum, 2-3
G
general wiring diagram, 9-12 ghosting defects, 5-16
I1
H
High Voltage Power Supply, disassembly, 7-75 horizontal image defects, 5-27 HVPS board locator map, 9-7 theory, 2-17 to Main Board Wiring Diagram, 9-13
I
image-quality defects, 5-2 Inner Cover, disassembly, 7-16 input capacity, tray, 1-10
Main Drive disassembly, 7-38 Solenoid, disassembly, 7-40 theory, 2-5 to Joint Board and Optional Tray Wiring Diagram, 9-15 maintenance preventive, 6-2 tools, 6-2 map column, 9-2 Menu map, 3-3 Microswitches, 2-14 Motor Drive Assemblies, 2-7 Motor tests, 3-8
O
OPC drum, 2-7 optional trays, 2-9 Outbin Full Assembly Actuator, disassembly, 7-45 Outbin Full Sensor, disassembly, 7-46 theory, 2-16 output capacity, tray, 1-10
J
Joint Board, disassembly, 7-52
K
Knock-Up Plate, disassembly, 7-17
P
P/J designators, 9-2 Paper feed sequence, 2-5 paper path, 2-4 paper path sensors, 2-15 Paper Size Sensor, 2-16 Paper Size Sensor, disassembly, 7-53 Paper Tray Assembly Paper Pick-up Process, 2-7 Paper Tray Empty Actuator, disassembly, 7-23 Paper Tray Empty Sensor, 2-15 Paper Tray Empty Sensor, disassembly, 7-22 Parts list, using, 8-4 Photo sensors, 2-13 Physical Specifications, 1-7 Pick-Up Assembly Pick Roller and Shaft, disassembly, 7-25 Pick Roller, disassembly, 7-28 Pick-Up Gear, disassembly, 7-34 Pick-Up Rack, disassembly, 7-18 Pick-Up Roller, 2-5 Plug Jack Designation diagrams, 9-2 locator table, 9-3 notation, 8-4 Pre-transfer Lamp disassembly, 7-50 theory, 2-2 preventive maintenance procedure, 4-3 Print cartridge defects, 5-3 theory, 2-3 print modes, 2-3
L
Laser Scan Unit (LSU) disassembly, 7-70 Laser exposure, 2-2 LSU Control tests, 3-10 LSU Lower Cover, disassembly, 7-72 Pre-transfer lamp, 2-2 theory, 2-7 Left Cover, disassembly, 7-7 light or undertone defects, 5-11 Locator Maps Map 1- LSU and Fuser, 9-4 Map 2 - Main Board, 9-5 Map 3 - SMPS Board, 9-6 Map 4 - HVPS Board, 9-7 LSU and Fuser locator map, 9-4 LSU and Main Motor to Main Board Wiring Diagram, 9-16
M
Main Assembly parts list, 8-7 view of parts, 8-6 Main Board disassembly, 7-39 theory, 2-6
I2
Printer, 1-4 location and clearance, 1-6 options and supplies, 1-2 orientation, 7-5 parts, 1-4 Physical specifications, 1-7 Print quality table, 1-8 Print resolution, 1-8 printer configurations, 1-2 specifications, 1-5 printer serial number, 8-2 Printing process, 2-2 Process Control fuser temperature, 2-12 laser scan, 2-11 light intensity, 2-11 paper pick, 2-10 paper size, 2-10 toner, 2-11 product symbols, 1-iv pulse width modulation, 2-8
service flowchart, 4-2 service procedures, 6-2 Service Terms manual terminology, 1-iii product terminology, 1-iii skew defects, 5-25 SMPS board locator map, 9-6 theory, 2-18 to Main Board Wiring Diagram, 9-13 Specifications environmental, 1-9 media and tray, 1-10 Sub Toner Low Sensor Board, disassembly, 7-24 Switched Mode Power Supply, disassembly, 7-76 switching mode, 2-18
T
Test print deletions, 5-4 fusing, 5-5 registration and skew, 5-6 resolution, 5-5 skips or smears, 5-8 Thermistor, 2-2, 2-5, 2-8, 2-14 toner development, 2-2 Tools, recommended, 4-3 Top Cover, disassembly, 7-10 Transfer Roller defects, 5-3 disassembly, 7-43 theory, 2-2, 2-8 transfer subsystem, 2-8 Tray 1 (MPT) disassembly, 7-14 Feed Sensor, 2-15 Feed Sensor, disassembly, 7-21 Paper Empty Sensor, 2-15 replacement, 7-15 Solenoid, disassembly, 7-29 Tray 2 assembly, parts list, 8-25 Cassette, view of parts, 8-24 Feed Roller, disassembly, 7-35 Pick Roller, disassembly, 7-35 Pick-Up Assembly, disassembly, 7-30 Tray 3 disassembly, 7-36 Tray 3 Cassette parts list, 8-27 view of parts, 8-26 Troubleshooting Control Panel, 4-4 image defects, 5-9 Power supplies, 4-5 print-quality, 5-2
R
RAM DIMM, 2-6 random spo defects, 5-20 Rear Cover, disassembly, 7-8 Registration Assembly, disassembly, 7-41 Regulatory Information, 1-ix repeating image defects, 5-22 Retard Assembly disassembly, 7-19 theory, 2-5 Right Cover, disassembly, 7-6
S
Safety precautions disconnecting power, 1-v electrostatic discharge, 1-vi general guidelines, 1-vii power safety, 1-v servicing compponents, 1-viii Sensors Sensor status, 3-6 to Main Board Wiring Diagram, 9-14 types, 2-13 Separation process, 2-7 Separator Pad Assembly, disassembly, 7-20 serial number location, 8-2 Service Diagnostic Front Panel Key Descriptions, 1-5, 3-4 service diagnostics menu, 3-3 service diagnostics, control panel, 3-3 service diagnostics, entering, 3-3
I3
U
unfused image defects, 5-24
V
voltage measurements, 4-5
W
Wiring diagrams Controller Unit and Duplex Board to Main Board, 9-17 HVPS/SMPS to Main Board, 9-13 LSU and Main Motor to Main Board, 9-16 Main Drive/Joint Board and Optional Tray, 9-15 notation, 9-8 Sensor to Main Board, 9-14
701P47822